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DOE OSTI2026

Enhancing microsegregation during rapid directional solidification through ternary microalloying

The nano-cellular dendritic microstructure formed during rapid directional solidification in powder bed fusion additive manufacturing creates unique properties such as simultaneous improvement in strength and ductility. However, process control of microsegregation features remains challenging due to low sensitivity of critical solidification mechanisms to process parameters. This study leverages microalloying to achieve large changes in dendrite composition, microstructure, and interdendritic zone width during laser powder bed fusion without modifying process parameters. CALPHAD simulations predict that the addition of Zr significantly steepens the solidus line of the dilute Cu-Cr alloy system, leading to enhanced Cr rejection into the melt and greater than 95% reduction in solubility of Cr in the solidified Cu matrix. Experimental validation using time-of-flight secondary ion mass spectrometry and Kelvin probe force microscopy reveals that the ternary alloy containing 0.01 wt% Zr exhibited wider interdendritic regions compared to the binary, a significantly higher number of Cr-rich particles within interdendritic regions, near-complete ejection of oxygen impurities from the matrix, and greater nanoscale work function contrast. These features indicate more aggressive Cr segregation in the presence of Zr and a purer Cu matrix and provide a potentially robust method for engineering the nano-cellular dendritic solidification microstructure.

CALPHAD↗

DOE OSTI2025

Laser powder bed fusion of ODS Fe–Cr–Al (0.3Zr, 0.3Y 2 O 3 ): Unveiling processing-microstructure- mechanical property relationships

Here, this study investigates the fabrication of oxide dispersion strengthened (ODS) Fe-Cr-Al alloys via laser powder bed fusion (LPBF) with strategic additions of 0.3 wt% Zr and 0.3 wt% Y 2 O 3 for enhanced mechanical performance in nuclear applications. Systematic processing parameter optimization yielded three distinct conditions: one low-density product with significant defects and two near-full-density materials with improved consolidation. Comprehensive characterization confirmed single-phase α-ferrite matrix formation with successful incorporation of Y-, Zr-, O-, and C-rich precipitates characteristic of ODS alloys. However, precipitate density remained low (∼10 7 cm −3 ), resulting in sink strength values substantially below optimal levels for radiation resistance. Microhardness values (mid-200s HV) correlated inversely with grain size following the Hall-Petch relationship, indicating grain boundary strengthening as the dominant mechanism rather than precipitation strengthening. The optimized processing conditions achieved excellent mechanical properties with room temperature yield strength of approximately 500 MPa and 30 % elongation, demonstrating superior strength-ductility synergy compared to other additively manufactured ODS materials and performance consistent with literature values for LPBF-processed ODS-FeCrAl alloys. This investigation reveals both the potential and limitations of LPBF processing for ODS Fe-Cr-Al alloys. While successful defect-free fabrication was achieved, results highlight the critical need for systematic optimization of processing parameters and post-processing heat treatments to enhance precipitate density for effective dispersion strengthening and radiation resistance while maintaining additive manufacturing advantages.

Additive manufacturing↗

DOE OSTI2023

Flexible all-organic nanocomposite films interlayered with in situ synthesized covalent organic frameworks for electrostatic energy storage

Poly(vinylidene fluoride)-based terpolymers, known for having the largest dielectric constant among the existing dielectric polymers, are attractive materials for electrostatic film capacitors used in lightweight electrification systems. However, the potential of these terpolymers in film capacitor applications remains constrained by their low electrical insulating and mechanical strengths. To address these limitations, we introduced rigid covalent organic framework (COF) nanospheres into the thin films of soft terpolymers via in situ synthesis and a facile layer-by-layer solution casting method, whereby multilayer films consisting of two polymer outer layers and a COF-containing middle layer were readily obtained. The resultant all-organic thin films exhibit simultaneously high dielectric constant, enhanced breakdown strength, superior energy density (~25 J cm –3 ) at efficiencies over 80%, along with greatly improved mechanical self-supporting capability and excellent mechanical flexibility. Here, this work demonstrates the unprecedented use of COF for electrostatic energy storage, uncovering its potential for flexible electronic applications operating under high electric fields.

25 ENERGY STORAGE↗

DOE OSTI2026

Conserving asphalt resources: Rethinking rejuvenator performance evaluation through peptizing efficiency

Timely rejuvenation and restoration of asphalt are essential conservation practices that help preserve and extend the service life of roads, bridges, driveways, and parking lots. The performance of asphalt rejuvenators is often assessed based on their diffusion rates and softening power, yet these metrics alone fail to capture true rejuvenation potential. Here, this study integrates density functional theory (DFT) modeling with experimental analysis to show that rejuvenation effectiveness is primarily governed by molecular interactions with oxidized asphaltene nanoaggregates. DFT results revealed that amide- and unsaturated-chain compounds, such as hexadecanamide, oleic acid, and 9,17-octadecadienal, act cooperatively to disrupt π–π stacking and exfoliate asphaltene layers, reducing binding strength and enhancing dispersion. Unlike bulky, rigid molecules that remain trapped, these components remain mobile and repeatedly interact with multiple aggregation sites. Experimental validation using rheometry and FTIR confirmed that such molecularly compatible rejuvenators restore the binder flexibility and polydispersity, even when diffusion is relatively slow. Building on this mechanistic foundation, six rejuvenators (A2, A5, A7, A8, A9, and A10) were evaluated using a three-metric performance framework encompassing cracking resistance (Glover–Rowe parameter), UV stability, and surface hydrophobicity. Among the six rejuvenators evaluated, A9 exhibited the highest overall performance, reducing the Glover–Rowe cracking parameter by 85% (from 351 kPa to 53 kPa), demonstrating the greatest resistance to UV-induced aging with a stability index of 4.17 h·kPa⁻¹, and increasing surface hydrophobicity to a contact angle of 103.6°. Its superior performance is primarily attributed to its amide- and unsaturated-chain components, which act cooperatively to disrupt π–π stacking interactions and exfoliate asphaltene layers, thereby promoting molecular deagglomeration and enhancing long-term durability. These results shift the criteria for selecting rejuvenators: effective candidates must pair the electronic capability to unlock aged asphaltenes with sufficient structural stability to resist secondary aging and restore hydrophobicity. Restoring hydrophobicity is critical, as aging reduces the asphalt’s water repellency and increases water diffusion, which in turn accelerates moisture-related damage; consequently, a high-performing rejuvenator must effectively restore the binder’s hydrophobic characteristic. Collectively, these findings provide a framework for the rational design of next-generation of bio-based rejuvenators that enhance pavement longevity and promote long-term sustainability.

Aging↗

DOE OSTI2026

Ion-Specific Effects on PuO 2 Nanoparticle Aggregation and Dissolution in Concentrated Electrolytes

Hydrolytic PuO 2 nanoparticles (NPs) are a dominant aqueous Pu-bearing phase in high ionic strength nuclear wastes, yet their reactivity in nonideal brines remains poorly constrained. We quantify how electrolyte identity and concentration control PuO 2 NP aggregation and ligand-assisted dissolution in acidic, high salinity solutions (NaCl, NaNO 3 , NaClO 4 , Na 2 SO 4 , Na 2 C 2 O 4 up to 5 M). A multitechnique workflow combining liquid scintillation counting (operationally defined aqueous [Pu]), scattering/electrokinetic measurements (aggregate size and zeta potential), and spectroscopy (UV–vis, XPS, Raman) resolves electrolyte-dependent partitioning between colloidal and molecular Pu species. Weakly coordinating anions (ClO 4 – , Cl – , NO 3 – ) largely preserve the (aggregated) nanoparticulate fraction but generate distinct dissolved species at high concentration, i.e., Pu(IV)–nitrato complexes in NaNO 3 and Pu(VI)–chloro complexes in NaCl. In contrast, stronger ligands substantially perturb PuO 2 NP stability: sulfate promotes partial dissolution to Pu(IV)–sulfate complexes at low concentration but reduces aqueous [Pu] at higher sulfate levels via secondary Pu(IV) sulfate formation, whereas oxalate drives strong dissolution to aqueous Pu–oxalate complexes. Aged NPs show similar trends with reduced aqueous fractions and more dominant aggregation mechanisms. In conclusion, these spectroscopically constrained speciation data provide a foundation for incorporating PuO 2 NP reactivity into thermodynamic and reactive transport models for high salinity waste and brine environments.

Aggregation↗

DOE OSTI2020

Strong Reduction in Amplitude of the Interfacial Segmental Dynamics in Polymer Nanocomposites

Despite the wide use of polymer nanocomposites (PNCs) in various applications, our understanding of the microscopic parameters controlling their macroscopic properties remains limited. In this study, we examine the dielectric strength of segmental dynamics, Δε IL (T) in the interfacial polymer layer surrounding the nanoparticles in PNCs. The presented analysis reveals a significant drop in Δε IL (T) and its anomalous temperature dependence in the polymer layer adsorbed to nanoparticles. The drop in Δε IL (T) was observed in all samples regardless of whether segmental relaxation time in the interfacial layer was slower or faster than in the bulk polymer, excluding interpretation of the “dead” layer. We ascribe the observed decrease in the dielectric strength to the restricted amplitude of segmental relaxation in the interfacial/adsorbed layer. Our results provide a new perspective on discussion of dynamics in the interfacial layer in PNCs and thin polymer films, demonstrating that not only segmental relaxation time but also its amplitude can be strongly affected by the interface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Efficiency-optimized relativistic plasma harmonics for extreme fields

Bright harmonic radiation from relativistically oscillating laser plasmas offers a direct route for generating extreme electromagnetic fields. Theory predicts that under optimized conditions, the plasma medium can support strong spatiotemporal compression of laser energy in a coherent harmonic focus (CHF), delivering intensity boosts many orders of magnitude greater than the incident driving laser pulse. Although diffraction-limited performance (spatial compression) and attosecond phase locking (temporal compression) have been demonstrated experimentally, efficient coupling of relativistically intense laser pulse energy into the emitted harmonic cone has not been realized so far. Here we demonstrate that this highly nonlinear interaction can be tailored to deliver the maximum conversion efficiencies predicted from simulations. By fine-tuning the temporal profile of the driving laser on sub-picosecond (<10 −12 s) timescales, energies >9 mJ between the 12th and 47th harmonics are observed. These results are in agreement with the theoretically expected efficiency dependence on harmonic order, verifying that optimal conditions have been achieved in the generation process. This is the important final element required to achieve the expected intensity boosts from a CHF in experiments. Although obtaining spatiotemporal compression and optimal efficiency simultaneously remains challenging, the path to realizing extreme optical field strengths approaching the critical field of quantum electrodynamics (the Schwinger limit at >10 16 V cm −1 or >10 29 W cm −2 ) is now open, permitting all-optical studies of the quantum vacuum and new frontiers for intense attosecond science.

High-harmonic generation↗

DOE OSTI2020

Investigations on the Thermal-hydraulic Behavior of Accident Tolerant Fuel Cladding Materials

Since the 2011 Fukushima accident, significant research has been devoted to developing accident-tolerant fuel (ATF) cladding materials. These investigations have mostly focused on the ability to resist runaway steam oxidation and retain mechanical strength and structural integrity under thermal shocks. However, much remains unknown about the materials’ thermal-hydraulic behavior, particularly under light-water reactor (LWR) operating conditions. Two phenomena that determine safety margins in both normal and off-normal operating conditions - i.e., the critical heat flux (CHF) and Leidenfrost point (LFP) temperature - have not been investigated thoroughly for ATF materials. Surface properties, such as wettability and roughness, are known to influence pool and flow boiling CHF, as well as the LFP temperature. However, little is known about the surface wettability of ATF materials, particularly at LWR pressure and temperature. Little has been done on flow-boiling CHF and quenching heat transfer, especially for droplet quenching. Nonetheless, it is known that CHF in transient conditions, e.g., an exponentially escalating power transient, can be significantly different from that expected in steady-state operation. Very few studies have investigated transient CHF, either on ATF materials or under LWR pressure and temperature. The thorough understanding of transient CHF under prototypical reactor conditions will benefit not only the deployment of ATF but also the upcoming national efforts to study transient ATF behavior in the Transient Reactor Test Facility (TREAT) at Idaho National Laboratory. In summary, as a part of ATF development efforts, there is an urgent need to understand how and how much these materials may affect two-phase heat transfer phenomena in nuclear reactor conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1991

Interaction of two glancing, crossing shock waves with a turbulent boundary-layer at various Mach numbers

A preliminary experimental investigation was conducted to study two crossing, glancing shock waves of equal strengths, interacting with the boundary-layer developed on a supersonic wind tunnel wall. This study was performed at several Mach numbers between 2.5 and 4.0. The shock waves were created by fins (shock generators), spanning the tunnel test section, that were set at angles varying from 4 to 12 degrees. The data acquired are wall static pressure measurements, and qualitative information in the form of oil flow and schlieren visualizations. The principle aim is two-fold. First, a fundamental understanding of the physics underlying this flow phenomena is desired. Also, a comprehensive data set is needed for computational fluid dynamic code validation. Results indicate that for small shock generator angles, the boundary-layer remains attached throughout the flow field. However, with increasing shock strengths (increasing generator angles), boundary layer separation does occur and becomes progressively more severe as the generator angles are increased further. The location of the separation, which starts well downstream of the shock crossing point, moves upstream as shock strengths are increased. At the highest generator angles, the separation appears to begin coincident with the generator leading edges and engulfs most of the area between the generators. This phenomena occurs very near the 'unstart' limit for the generators. The wall pressures at the lower generator angles are nominally consistent with the flow geometries (i.e. shock patterns) although significantly affected by the boundary-layer upstream influence. As separation occurs, the wall pressures exhibit a gradient that is mainly axial in direction in the vicinity of the separation. At the limiting conditions the wall pressure gradients are primarily in the axial direction throughout.

Hingst, Warren R.↗

DOE OSTI2025

Investigation of MgO additives on microstructure and properties of thin LLZO electrolytes for all-solid-state batteries

To realize high-energy density lithium lanthanum zirconate (LLZO)-based solid-state batteries (SSB), LLZO electrolytes should be fabricated with low thickness and high mechanical strength. An effective strategy for strengthening ceramic materials is to use additives. Here, we employed MgO nanopowders and fibers as additives for the thin LLZO electrolyte in order to improve the mechanical strength. The microstructure, mechanical properties, and electrochemical properties are characterized to investigate the effects of adding MgO and sintering time. The MgO remains at grain boundaries after sintering, making the microstructure of LLZO fine and uniform. The mechanical strength of the MgO-added LLZO was enhanced by more than 60% while maintaining high ionic conductivity (1 × 10 -4 S cm -1 ) at room temperature. Li symmetric cells using the MgO fiber–LLZO and MgO powder–LLZO exhibit 2 and 3 times higher critical current density (CCD) than those of pure LLZO, and a solid-state full cell exhibits stable cycling performance. Further, these results demonstrate that the use of MgO nanopowder or fiber as an additive for thin LLZO is beneficial for high-current density cycling, by improving mechanical properties and microstructure.

25 ENERGY STORAGE↗

NASA NTRS2016

[EC5-Space Suit Assembly Team- Internship]

There were three main projects in this internship. The first pertained to the Bearing Dust Cycle Test, in particular automating the test to allow for easier administration. The second concerned modifying the communication system setup in the Z2 suit, where speakers and mics were adjusted to allow for more space in the helmet. And finally, the last project concerned the tensile strength testing of fabrics deemed as candidates for space suit materials and desired to be sent off for radiation testing. The major duties here are split up between the major projects detailed above. For the Bearing Dust Cycle Test, the first objective was to find a way to automate administration of the test, as the previous version was long and tedious to perform. In order to do this, it was necessary to introduce additional electronics and perform programming to control the automation. Once this was done, it would be necessary to update documents concerning the test setup, procedure, and potential hazards. Finally, I was tasked with running tests using the new system to confirm system performance. For the Z2 communication system modifications, it was necessary to investigate alternative speakers and microphones which may have better performance than those currently used in the suit. Further, new speaker and microphone positions needed to be identified to keep them out of the way of the suit user. Once this was done, appropriate hardware (such as speaker or microphone cases and holders) could be prototyped and fabricated. For the suit material strength testing, the first task was to gather and document various test fabrics to identify the best suit material candidates. Then, it was needed to prepare samples for testing to establish baseline measurements and specify a testing procedure. Once the data was fully collected, additional test samples would be prepared and sent off-site to undergo irradiation before being tested again to observe changes in strength performance. For the Bearing Dust Cycle Test, automation was achieved through use of a servo motor and code written in LabVIEW. With this a small electrical servo controller was constructed and added to the system. For the Z2 communication modifications speaker cases were developed and printed, and new speakers and mics were selected. This allowed us to move the speakers and mics to locations to remain out of the suit users way. For the suit material strength testing, five material candidates were identified and test samples were created. These samples underwent testing, and baseline test results were gathered, though these results are currently being investigated for accuracy. The main process efficiency developed during the course of this internship comes from automation of the Bearing Dust Cycle Test. In particular, many hours of human involvement and precise operation are replaced with a simple motor setup. Thus it is no longer required to man the test, saving valuable employee time. This internship has confirmed a few things for me, namely that I both want to work as an engineer for an aerospace firm and that in particular I want to work for the Johnson Space Center. I am also confirmed in my desire to work with electronics, though I was surprised to enjoy prototyping 3D CAD design as much as I did. Therefore, I will make an effort to build my skills in this area so that I can continue to design mechanical models. In fact, I found the process of hands-on prototyping to be perhaps the most fun aspect of my time working here. This internship has also furthered my excitement for continual education, and I will hopefully be pursuing a masters in my field in the near future.

Maicke, Andrew↗

DOE OSTI2025

Strength, deformation, and the fcc–hcp phase transition in condensed Kr and Xe to the 100 GPa pressure range

The rare gas solids exhibit systematic differences in crystal structure, phase transition conditions, bond strength, and other physical properties. The physical properties of heavy rare gas solids krypton and xenon are modified by the martensitic phase transition from face-centered cubic to hexagonal close packed structure over a broad pressure range. Crystal structure, strength, and plastic deformation of krypton and xenon have been investigated at 300 K using compression in the diamond-anvil cell with synchrotron angle-dispersive x-ray diffraction and complementary ruby fluorescence spectroscopy for Xe. Stacking faults indicative of the fcc–hcp phase transition are observed at pressures at and above 1.23 ± 0.05 and 1.9 ± 0.6 GPa in Kr and Xe, respectively. The transition remains incomplete in both solids to pressures greater than 100 GPa. Strength determined from stress measurements in Pt and ruby standards at pressures up to 111 GPa and complemented by observations of strain and texture measurements obtained by x-ray diffraction in the radial geometry to 100 GPa indicates similar or higher strength than Ar at all conditions, with significant stiffening at 15–20 GPa. Radial diffraction data reveal the persistence of broad highly textured fcc diffraction lines to 101 GPa in Xe, suggesting that the axial measurements may underestimate the metastable persistence of the fcc phase due to biased sampling of hcp crystallites resulting from preferred crystallite orientation. Kr and Xe are compared with He, Ne, and Ar for a systematic understanding of physical properties and phase equilibria of rare gas solids.

Compressive stress↗

DOE OSTI2023

Type 5 Wind Turbine Technology: How Synchronised, Synchronous Generation Avoids Uncertainties About Inverter Interoperability under IEEE 2800:2022

Degradation of system strength because of inverter-based resources (IBRs) is a major concern facing the zero-carbon transition. A new standard released this year, IEEE Standard 2800, attempts to codify the relationship between IBRs and the Transmission System Operator (TSO). It is apparent from IEEE 2800:2022 that there remain fundamental problems with quantifying whether source impedance (the measure of "system strength" with which the standard is concerned) will present a problem for allowing an IBR to connect. This is "because of complex interdependencies between IBR and power system characteristics". So developers are increasingly required to adopt mitigation options such as adding synchronous condensers or curtailing IBRs. A proven Type 5 (synchronous) wind turbine exists and has been running at 0.5 MW scale in a 46 MW wind farm in New Zealand since 2006 and eight turbines in Scotland since 2013. The US National Renewable Energy Laboratory (NREL) is conducting a study of the impacts on grid reliability, stability, and resilience of Type 5 wind turbines. The project has both simulation and testing tasks and will result in proposing a variable generation solution that will help system operators and utilities address all reliability and most resilience challenges in the evolving grid.

grid stability↗

NASA NTRS2012

Axisymmetric Flow Properties for Magnetic Elements of Differing Strength

Aspects of the structure and dynamics of the flows in the Sun's surface shear layer remain uncertain and yet are critically important for understanding the observed magnetic behavior. In our previous studies of the axisymmetric transport of magnetic elements we found systematic changes in both the differential rotation and the meridional flow over the course of Solar Cycle 23. Here we examine how those flows depend upon the strength (and presumably anchoring depth) of the magnetic elements. Line of sight magnetograms obtained by the HMI instrument aboard SDO over the course of Carrington Rotation 2097 were mapped to heliographic coordinates and averaged over 12 minutes to remove the 5-min oscillations. Data masks were constructed based on the field strength of each mapped pixel to isolate magnetic elements of differing field strength. We used Local Correlation Tracking of the unmasked data (separated in time by 1- to 8-hours) to determine the longitudinal and latitudinal motions of the magnetic elements. We then calculated average flow velocities as functions of latitude and longitude from the central meridian for approx 600 image pairs over the 27-day rotation. Variations with longitude indicate and characterize systematic errors in the flow measurements associated with changes in the signal from disk center to limb. Removing these systematic errors reveals changes in the axisymmetric flow properties that reflect changes in flow properties with depth in the surface shear layer.

Rightmire-Upton, Lisa↗

DOE OSTI2026

Hydrogen production from full-strength corn stover fermentation effluent in single-chamber replaceable-cathode microbial electrolysis cells

Lignocellulosic residual biomass generated by the agricultural sector is an abundant feedstock for biohydrogen production via dark fermentation. However, this process is intrinsically inefficient, converting only ~30% of the reductant energy into H2 and leaving substantial amounts of reduced byproducts. These byproducts, mostly found in the fermentation effluents, can be further valorized in microbial electrolysis cells (MECs) to enhance the overall H2 recovery. However, current MEC configurations are typically dual- or single-chamber systems, yet both suffer from key inefficiencies. Dual-chamber systems rely on proton exchange membranes that are costly and prone to rapid biofouling, whereas single-chamber, membraneless systems are limited by reduced productivity due to H2 recycling and methanogenic consumption In this study, three single-chamber, 50-mL replaceable-cathode microbial electrolysis cells (RC-MECs) were 3D-printed and equipped with a physical separator to isolate anode and cathode compartments and limit H2 migration. Full-strength milled corn stover (MCS) fermentation effluent (COD of ~23.8 g-COD/L) was treated in fed-batch mode over two operational periods spanning 21 (Run 1) and 80 (Run 2) days. The RC-MECs exhibited comparable performance in both runs: after biofilm maturation, current densities exceeded 100 A/m²_cathode, COD removal reached up to 43%. Notably, extended RC-MECs operation led to a substantial methanogenic activity with the CH4 fraction in the cathode gas increasing to as high as 80% of the total biogas. Additions of a methanogenesis inhibitor 2-bromoethanesulfonate (2-BES) produced transient increases in hydrogen yields (11.51 and 5.12 L-H2/L_reactor/day in Runs 1 and 2, respectively); however, sustained 2-BES addition in subsequent cycles reduced total biogas production, decreased COD removal, and led to volatile fatty acid accumulation. Overall, single-chamber MECs can treat high-strength dark fermentation effluents while improving H2 recovery, but methanogenesis remains a key bottleneck, and complete long-term inhibition may be operationally unsustainable.

Hydrogen Production↗

DOE OSTI2025

Best practices for in-situ and operando techniques within electrocatalytic systems

In-situ and operando techniques in heterogeneous electrocatalysis are a powerful tool used to elucidate reaction mechanisms. Ultimately, they are key in determining concrete links between a catalyst’s physical/electronic structure and its activity en route to designing next-generation systems. To this end, the exact execution and interpretation of these lines of experiments is critical as this determines the strength of conclusions that can be drawn and what uncertainties remain. Instead of focusing on how techniques were used to understand systems, as is the case with most reviews on the topic, this work instead initiates a nuanced discussion of 1) how to best carry out each technique and 2) initiate a nuanced analysis of which level of insights can be drawn from the set of in-situ or operando experiments/controls carried out. We focus on several commonly used techniques, including vibrational (IR, Raman) spectroscopy, X-ray absorption spectroscopy and electrochemical mass spectrometry. In addition to this, we include sections of reactor design and the link with theoretical modelling that are applicable across all techniques. While we focus on heterogeneous electrocatalysis, we make links when appropriate to the areas of photo- and thermo-catalytic systems. We highlight common pitfalls in the field, how to avoid them, and what sets of complementary experiments may be used to strengthen the analysis. We end with an overview of what gaps remain in in-situ and operando techniques and what innovations must be made to overcome them.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Controlling Deformation in Al/Ti: How Interface Roughness and Orientation Drive Bimetal Mechanics

The microstructural characteristics and morphology of interfaces in metals can be crucial in governing the initiation of plasticity and early deformation mechanisms under extreme conditions. During high-strain-rate deformation, these interfaces significantly affect dislocation nucleation, twinning, and other mechanisms that directly impact material strength and failure. Despite their importance, a substantial knowledge gap remains between the observed macroscopic material behavior and the underlying role of bimetal interfaces in plasticity initiation. Here, to address this gap, large-scale molecular dynamics simulations are performed on Al/Ti bimetal structures to examine the effect of interface characteristics on the onset of plasticity under uniaxial compression. Specifically, this study investigates how interface roughness (flat vs waveform interfaces) modifies the initiation of plastic events in the microstructure. Atomistic simulations indicate that interface roughness (a microscopic behavior) reduces the stress required for dislocation nucleation, thereby reducing the peak stress relative to a flat interface. For the square interface, the step height strongly influences plasticity initiation by setting the separation of locally flat regions. Varying the interface rotation relative to the loading direction (macroscopic behavior) reveals that the peak stress for both flat and waveform interfaces initially decreases and then increases with rotation, accompanied by a shift in dominant mechanisms—from Al twinning (flat) to interface sliding and Ti-dominated phase transformation and twinning at lower angles. The change in the stress-strain slope during initial compression reflects how rotation alters the resolved shear stress and activates different slip systems. Overall, the study provides valuable insights into the role of bimetal interfaces in controlling plasticity initiation and early deformation pathways for Al/Ti under extreme loading conditions.

36 MATERIALS SCIENCE↗

NASA NTRS2008

Composite Materials for Low-Temperature Applications

Composite materials with improved thermal conductivity and good mechanical strength properties should allow for the design and construction of more thermally efficient components (such as pipes and valves) for use in fluid-processing systems. These materials should have wide application in any number of systems, including ground support equipment (GSE), lunar systems, and flight hardware that need reduced heat transfer. Researchers from the Polymer Science and Technology Laboratory and the Cryogenics Laboratory at Kennedy Space Center were able to develop a new series of composite materials that can meet NASA's needs for lightweight materials/composites for use in fluid systems and also expand the plastic-additive markets. With respect to thermal conductivity and physical properties, these materials are excellent alternatives to prior composite materials and can be used in the aerospace, automotive, military, electronics, food-packaging, and textile markets. One specific application of the polymeric composition is for use in tanks, pipes, valves, structural supports, and components for hot or cold fluid-processing systems where heat flow through materials is a problem to be avoided. These materials can also substitute for metals in cryogenic and other low-temperature applications. These organic/inorganic polymeric composite materials were invented with significant reduction in heat transfer properties. Decreases of 20 to 50 percent in thermal conductivity versus that of the unmodified polymer matrix were measured. These novel composite materials also maintain mechanical properties of the unmodified polymer matrix. These composite materials consist of an inorganic additive combined with a thermoplastic polymer material. The intrinsic, low thermal conductivity of the additive is imparted into the thermoplastic, resulting in a significant reduction in heat transfer over that of the base polymer itself, yet maintaining most of the polymer's original properties. Normal polymer processing techniques can turn these composite materials into unique, custom parts for ground support, Shuttle, and Constellation needs. We fabricated test specimens of the composite and base materials for thermal and mechanical characterization and found that the strength of the composite material at nominal-percentage loading remained relatively unchanged from the base material.

Source record↗