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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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DOE OSTI2024

CORE-CM in The Greater Green River and Wind River Basins: Transforming and Advancing a National Coal Asset (Final Report)

The following document summarizes project results from “CORE-CM in the Greater Green River and Wind River Basins: Transforming and Advancing a National Coal Asset”. This project is part of the U.S. Department of Energy’s (“DOE”) National Energy Technology Laboratory’s (“NETL”) Carbon Ore, Rare Earth Elements, and Critical Minerals (CORE-CM) Initiative. This report concludes that the Greater Green River and Wind River Basins (GGRB-WRB) Area-of-Interest (AOI 9) is the ideal region for continued research and development in progressing the broader CORE-CM goals outlined by the DOE. Based upon the extensive analyses of technical, social, and community criteria, this report illustrates that the GGRB-WRB hosts numerous potential CORE-CM feedstocks (both coal- and non-coal based), diverse opportunities for utilizing existing industrial waste streams, ample infrastructure and industry to support new CORE-CM-focused technologies, and a highly motivated, well educated, and adaptable workforce to further develop the regional and national CORE-CM supply chain. Additionally, some potential solutions for technological gaps suggest that the GGRB-WRB's diverse resources can play a significant role in achieving the national goal of critical materials independence. With full community participation, meaningful involvement of regional Tribal Nations, and building upon the stakeholder engagement demonstrated here, the GGRB-WRB region presents a unique opportunity for advancing the CORE-CM Initiative. This project was designed to bring together coal-based communities and stakeholders from across the GGRB-WRB to advance new industries for CORE-CM resources. The University of Wyoming (UWyo) School of Energy Resources (SER) led a project team of experts from the Colorado Geological Survey (CGS), Colorado School of Mines (CSM), Los Alamos National Lab (LANL), and local community colleges. Input from basinal, regional, and national experts bolstered the coalition in order to advance the mission of DOE’s CORE-CM initiative and develop the domestic CORE-CM supply chain. Phase I of this project was designed to address the goal of developing and catalyzing economic growth, job creation, and technology innovation in the GGRB-WRB of Wyoming and Colorado, by increasing the supply of CORE-CM to manufacturers of non-fuel Carbon Based Products (CBP) and products reliant upon CM. The GGRB-WRB CORE-CM project worked toward providing benefit through several avenues of performance and research. • Develop a coalition team to achieve project objectives • Complete detailed assessments, including State-of-the-Art (SOTA) Data acquisition of potential CORE-CM materials across the AOI, and meaningfully contributes to DOE’s CORE-CM goals nationally. • Strategic planning for regional economic growth, job creation, and associated technology innovation around coal materials, including plans to maximize the development of potential CORE-CM resources and technology by creating regional public-private partnerships. • Define regional economic growth potential around existing strengths, energy infrastructure, business and industry, including planning for the leveraging of highly trained workforces, existing and novel coal technologies, and energy infrastructure in development of CORE-CM supply chains. • Develop a preliminary strategic plan for increasing the supply of CORE-CM materials to manufacturers of non-fuel Carbon Based Products (CBP) and products reliant upon CM, focusing on regional strengths that result in an emerging diversified CORE-CM economy. • Assemble a committed network of stakeholders and communities that learn about, accept, and grow new energy technologies within coal regions. Additionally, the project team significantly contributed to the CORE-CM Initiative’s national goals, through cross-regional scoping, collaborating with CORE-CM projects in other AOIs, and including parallel regional project experts. In addition to active inclusion and meaningful engagement and contribution to DOE-led working groups, the project team focused on engaging with regional communities including Tribal Nations, economic development groups, and regional government organizations. The project’s CORE-CM development and commercialization plan identified diverse CORECM feedstocks, potential routes towards integration with existing industries, methods for supply-chain development that leverage existing infrastructure and businesses considering the regional economy, identified entry barriers for incorporating traditional and new technologies in those supply chains, recognized opportunities for public-private partnerships to develop technology innovation centers, identified diverse workforces, and conducted stakeholder outreach and education to build a community of understanding on CORE-CM potential in the GGRB-WRB region. Detailed task descriptions can be found in each chapter.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Illuminating the Material World: Autonomous Microscopy to Understand Order, Disorder, and Everything In Between

Artificial intelligence (AI) holds immense promise for revolutionizing microscopy, yet its widespread adoption has been hindered by challenges ranging from user inexperience to limited model transferability and difficulties in operationalizing machine learning. This presentation showcases our approach to developing practical autonomy for materials discovery, aiming to accelerate the integration of AI into everyday microscopy workflows. As shown in Fig. 1, I will focus on three key areas: understanding order-disorder transitions, quantifying point defects, and achieving truly device-scale microscopy. First, I will demonstrate the power of multi-modal knowledge graphs for integrating diverse microscopy data. By combining imaging, spectroscopy, and diffraction data, these graphs provide a holistic view of material behavior, capturing the intricate relationships between different modalities [1,2]. I will present a case study on how these models illuminate the structural and chemical changes associated with irradiation in oxide thin films, revealing critical insights for designing materials for extreme environments like spaceflight and nuclear energy. Specifically, I will show how multi-modal analysis clarifies the evolution of order-disorder transitions under irradiation, a key factor influencing material performance in these applications. Next, I will address the challenge of quantifying point defects in 2D materials. We demonstrate the application of computer vision and transfer learning to accurately identify and classify various defect types, such as vacancies and substitutional atoms, and to quantify their concentrations. This information is crucial for understanding and tailoring the properties of 2D materials for applications in electronics, optoelectronics, and catalysis. For example, I will show how our models can characterize the topological distribution of point defects in MXene transition metal carbides, providing valuable insights for optimizing their performance in energy storage and separation science. Finally, I will discuss our progress toward autonomous device-scale microscopy [3,4]. We are fundamentally redesigning electron microscopes around the principles of machine reasoning, enabling automation beyond basic tasks like sample navigation and data acquisition to include sophisticated experimental design. This approach paves the way for truly reproducible and massively scaled analysis campaigns. I will emphasize the importance of autonomous microscopy platforms for high-throughput materials discovery and characterization, facilitating the rapid screening of materials for a broad range of applications and accelerating the development of next-generation technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2017

A Phase-Field Model for the U-Pu-Zr System

Modeling nuclear materials is a multi-scale, multi-physics endeavor. Researchers are currently investigating how bulk material properties are affected by the evolution of microscopic material structures, i.e. microstructures. Development of tools that can mechanistically predict the effects of processes like diffusion and grain growth on properties like thermal conductivity will transform nuclear material design, manufacturing, and use. Intermediate-scale, i.e. mesoscale, modeling is among the most promising tools available for this task. Expedited development of mesoscale models, however, will require structured collaboration between modelers and experimentalists. Coupling these fields promises to improve both model accuracy and experiment design. With these ideas in mind, a mesoscale model of the U-Pu-Zr system is being developed. Its development will accompany a series of experiments involving irradiation of metallic fuel samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Alternate Reductant Cold Cap Evaluation Furnace Phase II Testing

Savannah River Remediation (SRR) conducted a Systems Engineering Evaluation (SEE) to determine the optimum alternate reductant flowsheet for the Defense Waste Processing Facility (DWPF). Specifically, two proposed flowsheets (nitric–formic–glycolic and nitric–formic–sugar) were evaluated based upon results from preliminary testing. Comparison of the two flowsheets among evaluation criteria indicated a preference towards the nitric–formic–glycolic flowsheet. Further research and development of this flowsheet eliminated the formic acid, and as a result, the nitric–glycolic flowsheet was recommended for further testing. Based on the development of a roadmap for the nitric–glycolic acid flowsheet, Waste Solidification Engineering (WS-E) issued a Technical Task Request (TTR) to address flammability issues that may impact the implementation of this flowsheet. Melter testing was requested in order to define the DWPF flammability envelope for the nitric-glycolic acid flowsheet. The Savannah River National Laboratory (SRNL) Cold Cap Evaluation Furnace (CEF), a 1/12 th scale DWPF melter, was selected by the SRR Alternate Reductant project team as the melter platform for this testing. The overall scope was divided into the following sub-tasks as discussed in the Task Technical and Quality Assurance Plan (TTQAP): Phase I - A nitric–formic acid flowsheet melter test (unbubbled) to baseline the CEF cold cap and vapor space data to the benchmark melter flammability models; Phase II - A nitric–glycolic acid flowsheet melter test (unbubbled and bubbled) to: Define new cold cap reactions and global kinetic parameters in support of the melter flammability model development; Quantify off-gas surging potential of the feed; Characterize off-gas condensate for complete organic and inorganic carbon species. After charging the CEF with cullet from Phase I CEF testing, the melter was slurry-fed with glycolic flowsheet based SB6-Frit 418 melter feed at 36% waste loading and was operated continuously for 25 days. Process data was collected throughout testing and included melter operation parameters and off-gas chemistry. In order to generate off-gas data in support of the flammability model development for the nitric-glycolic flowsheet, vapor space steady state testing in the range of ~300-750°C was conducted under the following conditions, (i) 100% (nominal and excess antifoam levels) and 125% stoichiometry feed and (ii) with and without argon bubbling. Adjustments to feed rate, heater outputs and purge air flow were necessary in order to achieve vapor space temperatures in this range. Surge testing was also completed under nominal conditions for four days with argon bubbling and one day without argon bubbling.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

Extracting physics through deep data analysis

In recent decades humankind has become very apt at generating and recording enormous amounts of data, ranging from tweets and selfies on social networks, to financial transactions in banks and stores. The scientific community has not shunned this popular trend and now routinely produces hundreds of petabytes of data per year [1]. This is because materials and phenomena in the world around us exist in an interweaved, entangled form, which gives rise to the complexity of the Universe and determines the size and complexity of the data that describes it. Science and technology endeavor to unravel this convolution and extract pure components from the mixtures, be it in ore mining and metal smelting or separation of thermal conductivity into the electronic and phononic contributions. Decomposition of complex behavior is the key to understanding manifestations of Nature. However, tools to carry out this task are not readily available, and therefore, intricate systems often remain well-characterized experimentally, but still not well understood due to intricacy of the collected data. Lastly, in materials science, understanding and ultimately designing new materials with complex properties will require the ability to integrate and analyze data from multiple instruments, including computational models, designed to probe complementary ranges of space, time, and energy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Epitaxial Growth Development: CRADA Final Report

The purpose of this CRADA is to assist Trumpf Photonics in developing a procedure to grow ZnSe epilayers on the (110) facets of AlGaAs/InGaAs laser diodes that will provide high degrees of electronic passivation and performance reliability. Work will be divided into four tasks: 1) characterization of material growth at Trumpf Photonics, 2) development of a highly effective AlGaAs facet cleaning procedure at NREL, 3) development of a ZnSe epitaxy procedure at NREL, and 4) transfer of the procedures developed at NREL to the Trumpf Photonics site. This CRADA is designed to last 3 years total.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Aluminum Spent Fuel Performance in Dry Storage Task 4 Aluminum Oxide Sampling of ATR Dry Stored Fuel

Milestone report on sampling of long-term dry-stored ATR spent fuel elements. It describes tooling, sample acquisition methods and analysis of the aluminum oxide samples by scanning electron microscopy, thermogravimetric analysis, X-ray diffraction and transmission electron microscopy. The observations provide input to projections on controls necessary for maintaining the integrity of the fuel during extended interim storage.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Low-Cost Aero Technology Demonstrations

The main focus of this work was to demonstrate the use of polymeric additive manufacturing (AM) to create tooling for both preforming and consolidation. Polymeric tooling was utilized where both modest and higher pressures are used for part consolidation. The key focus for the AM tooling development was for fabrication of complex structures such as ducting, C-channel stiffened skins, and airfoils where conventional male tooling would typically be trapped in the cured part. The AM tooling was evaluated for use as a tool master used to fabricate and re-shape deformable/re-formable mandrels based on SpinTech’s shape memory composite technology known as Smart Tooling. The AM tooling was also evaluated for use as a mold for composite infusion and consolidation. Key performance parameters were tracked for project schedule completion with each step comprising of “art to part” cycle time, cost, and model fidelity for dimensions, performance, and cost. The primary focus of this demonstration was to determine if a 50% cost reduction was achievable, for each AM tooling-set, as compared to conventional processes. UDRI leveraged project partner SpinTech, who manufactures tools and parts in these categories and thus provided a baseline regarding current best practices and provided valuable feedback during the entirety of this demonstration. This demonstration primarily focused on the use of AM tooling for fabrication of three composite component structures which are typically utilized in aircraft and comprise salient geometric features of broad interest. These components are often tooling intensive and have features requiring extraction of male tools which are usually trapped by the geometry. The three structures selected by the team included: 1) A one-piece airfoil shell comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves as is typically the case. 2) A one-piece duct used for air handling, comprised of compound contours where male tooling would be trapped unless the part were manufactured in two halves, or a washout mandrel were to be used. 3) A co-cured C-channel stiffened skin where typically C-channels would be individually manufactured and then bonded to a cured skin. The demonstration was comprised of three main tasks: • Task 1: AM Tool Feasibility Study – ensure the AM tooling meets the performance requirements as specified by SpinTech to match baseline performance. • Task 2: Complex Tool Demonstration – Fabricate tooling, preforms, and parts representative of an airfoil and duct. • Task 3: Large Aerostructure Fabrication Demonstration – Fabricate tooling, preforms, and part representative of a C-channel stiffened skin. With the conclusion of this project, a decision tree was developed to determine the key considerations necessary to determine if use of AM tooling for the three selected structures was able to attain the same quality as historically achieved on metallic tooling, while providing a significant cost reduction.

36 MATERIALS SCIENCE↗
DOE OSTI2018

On the Variation of Hardness Due to Uniaxial and Equi-Biaxial Residual Surface Stresses at Elastic–Plastic Indentation

It is established long since that the material hardness is independent of residual stresses at predominantly plastic deformation close to the contact region at indentation. Recently though, it has been shown that when elastic and plastic deformations are of equal magnitude this invariance is lost. For materials such as ceramics and polymers, this will complicate residual stress determination but can also, if properly understood, provide additional important information for performing such a task. Indeed, when the residual stresses are equi-biaxial, the situation is quite well understood, but additional efforts have to be made to understand the mechanical behavior in other loading states. Presently therefore, the variation of hardness, due to residual stresses, is examined at a uniaxial stress state. Correlation with global indentation quantities is analyzed, discussed and compared to corresponding equi-biaxial results. Cone indentation of elastic–perfectly plastic materials is considered.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Illinois Basin Regional DAC Hub TA-1: Feasibility (Phase-0) (Final Scientific/Technical Report)

The overall objective of this project was to complete a feasibility study for a Regional Direct Air Capture (DAC) Hub that encompasses Illinois, Indiana, and Kentucky. The geographic construct of this hub was based on the Illinois Basin – a geological area where at least seven (7) geological storage studies were conducted. The Hub was designed to assure a capacity to capture, store, and utilize at least 1,000,000 metric tons (tonnes) of CO2 from the atmosphere annually 1 metric tonnes per annum (MTA), starting from an initial capacity of 200,000 tonnes of CO2 per annum (KTA). The Hub also included:(1) clean energy providers to supply renewable energy to the DAC units; (2) geological storage facilities to inject and sequestrate the captured CO2; (3) CO2 utilization facilities that would uptake the captured CO2 and convert it into products; and (4) small business organizations that would assist in workforce development efforts for the region. This closeout report consolidates the tasks undertaken and accomplished as deliverables for the project. The project team had successfully completed all required tasks of phase 0a, confirming that the project is feasible based on the preliminary conceptual designs and operational requirements of the DAC systems. Of particular interest, the hub ownership structure was identified and was implemented in follow on projects that would transition the hub infrastructure to a build/operate phase.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Calculation of reinforced-concrete frame strength under a simultaneous static cross section load and a column lateral impact

When designing buildings with reinforced concrete that are planned to resist dynamic loads it is necessary to calculate this structural behavior under operational static and emergency impact and blast loads. Calculations of the structures under shock-wave loads can be performed by solving dynamic equations that do not consider static loads. Due to this fact the calculation of reinforced concrete frame under a simultaneous static and dynamic load in full 3d settings becomes a very non trivial and resource consuming problem. This problem can be split into two tasks. The first one is a shock-wave problem that can be solved using software package RANET-3, which allows solving the problem using finite elements method adapted for dynamic task. This method calculates strain-stress state of the material and its dynamic destruction, which is considered as growth and consolidation of micro defects under loading. On the second step the results of the first step are taken as input parameters for quasi static calculation of simultaneous static and dynamic load using finite elements method in AMP Civil Engineering-11.

36 MATERIALS SCIENCE↗
DOE OSTI2016

FY16 Status Report for the Uranium-Molybdenum Fuel Concept

The Fuel Cycle Research and Development program of the Office of Nuclear Energy has implemented a program to develop a Uranium-Molybdenum metal fuel for light water reactors. Uranium-Molybdenum fuel has the potential to provide superior performance based on its thermo-physical properties. With sufficient development, it may be able to provide the Light Water Reactor industry with a melt-resistant, accident-tolerant fuel with improved safety response. The Pacific Northwest National Laboratory has been tasked with extrusion development and performing ex-reactor corrosion testing to characterize the performance of Uranium-Molybdenum fuel in both these areas. This report documents the results of the fiscal year 2016 effort to develop the Uranium-Molybdenum metal fuel concept for light water reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Further Support of the Development of Advanced Multilayer Optics Coatings for X-Ray Imaging

SAO is working with LLNL to develop Wolter-I optics for x-ray imaging applications at energies of 15-50 keV and above at NNSA facilities. Our work includes R&D on advanced multilayer coatings as well as fabrication and testing of Wolter-I multilayer coated optics. It also includes delivery of custom 3.05-meter focal length Wolter optics with response at energies of interest to Sandia National Laboratories and LLNL. The mandrels for the custom optics are fabricated at MSFC. In previous contracts, SAO delivered several optics to LLNL with response at various energies. During this present contract period two tasks were carried out. Task1: the coating, replication and characterization of a custom optic with peak response at 22.8 keV, using the custom-designed SANZ mandrels. Task2: carrying out modifications to the coating chamber at SAO to accommodate new, longer, custom-designed mandrels (SANZlong) that will be fabricated at NASA MSFC in FY2020. The longer mandrels are necessary to mitigate end effects observed in the replication process for the small optics currently being fabricated.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Additive Manufacturing of Thermoset Cellular Structures

Magnum Venus Products (MVP) and Oak Ridge National Laboratory (ORNL) set out to develop and commercialize a 3D printer depositing thermoset polymers with a build volume accommodating mid-scale applications capable of deposition rate exceeding 10 lb/hr with resolution of 3 mm or less. The objective of this work was to demonstrate the ability to efficiently print light weight cellular structures for application in load bearing structural applications, thereby transforming the mid to large scale additive technology. The project was organized around three main tasks: 1. Thermoset printer development, 2. Material and process parameter development and 3. Demonstration. The MVP-ORNL team successfully carried out the project by creating the first thermoset 3D printer of this size in the world and by using it to demonstrate the ability to print cellular structures. The team was awarded the Award for Composites Excellence at the 2018 CAMX conference for this development.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Planned FY19 Creep and Fatigue Design Curve Testing of Alloy 709 Base Metal

This report summarizes the status of planned FY 2019 creep and fatigue testing of the first commercial heat of Alloy 709 base metal at Oak Ridge National Laboratory (ORNL). A comprehensive master creep testing matrix was generated to support the ASME code qualification of Alloy 709. The testing activities and research are carried out at Argonne National Laboratory, Idaho National Laboratory and ORNL. ORNL was tasked to carry out a subset of the creep Code Case testing matrix for electroslag remelt (ESR) with solution annealing (S/A) at 1100°C in FY 2019. In this reporting cycle, 25 creep tests were started and 9 of them produced rupture data. The remaining 16 tests of ESR with S/A at 1100°C, along with 6 long-term creep tests of argon-oxygen-decarburization with S/A at 1100°C, are ongoing.

36 MATERIALS SCIENCE↗