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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Guidelines for Making, Interpreting, and Quantifying Activity Measurements of Molten Salts Containing Mixed Cations and Anions Using Cation-Based Electrodes by Electromotive Force

Measurements of thermochemical properties in molten salt electrolytes with mixtures of cations and anions are difficult to interpret. Electromotive force measurements of salts containing common anions were driven by the least stable anion compound (e.g., LiCl in LiCl-KCl), while measurements in common cation salts were driven by the most noble anion half-cell reaction (e.g., F − /F 2 in LiCl-LiF). Measurements in mixed cation and anion salts were driven by the least stable anion compound for the most noble anion half-cell reaction (e.g., KF in KCl-LiF). These guidelines enable quantification of the activity of electroactive species in salts containing multiple cations or anions.

Lichtenstein, Timothy [Argonne National Laboratory↗
DOE OSTI2025

Geometric control of magnetic domain morphology in electrodeposited Ni rich NiPt mesoscopic wires

In this paper, we study the electrodeposited Ni—Pt magnetic wires, exploring the mechanisms by which changes in geometry and composition influence the local magnetic structure. The samples were prepared by electrodeposition, their elemental composition was analyzed by energy dispersive X-ray spectroscopy, and phase analysis was carried out by an X-ray diffraction measurement. Magnetic force microscopy measurements, and magnetic force microscopy measurements in magnetic field were carried out to study the domain morphology of the prepared samples. Magnetization characteristics were measured via vibrating sample magnetometry mode of a superconducting quantum interference device. Here, the results were analyzed and compared with micromagnetic simulations. It is shown that a strong perpendicular magnetic anisotropy is responsible for the characteristic checkerboard-like surface magnetization patterns, which can be tuned by geometrical constriction and Ni content. Understanding these relationships provides insights into the design of magnetic materials with tailored properties for advanced applications, like magnetic sensors.

Binary alloy↗
DOE OSTI2025

Effect of tert -Butyl Substitution on the Interactions of Cobalt Phthalocyanine with a Carbon Monoxide-Functionalized Tip

Supported cobalt phthalocyanines (CoPc) are promising catalysts for CO 2 reduction, a critical process for mitigating greenhouse gas emissions. Enhancing the catalytic performance of CoPc involves modifying the interaction between the cobalt center and intermediate species. This study focuses on the effects of tert-butyl substitution on CoPc using (tert-butyl) 4 CoPc, where the substitution can both directly alter the molecule’s intramolecular electronic structure and indirectly alter it by the bulky group weakening the interaction with the support. Toward this end, we investigated the structural and chemical properties of (tert-butyl) 4 CoPc on a Ag(111) surface at the single-molecule level using three-dimensional atomic force microscopy (AFM) with a CO-terminated tip and discussed them in comparison with data for unmodified CoPc and amino-substituted CoPc. Notably, distance-dependent force measurements revealed anomalies in the tert-butyl groups’ force curves, attributed to their rotational flexibility. The tert-butyl (t-butyl) groups were also observed to increase the attraction of the central Co atom to CO, but this effect was attributed largely to enhanced interactions of the back of the tip with the peripheral t-butyl groups. In conclusion, while this longer-range interaction would not be expected to impact the interaction of small molecules with the catalytic center, the results reveal the ability of AFM to characterize longer range environmental interactions that can enhance adsorption and subsequent reactions of larger molecules, as well as the role side chains that offer configurational adaptability may play in these interactions.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2026

Influence of Nanoconfinement and Elevated Temperatures on Geocolloid-Facilitated Transport of Energy-related Contaminants

The main objective of this project is to obtain a better understanding of the transport behavior and interactions of geocolloids in the presence of energy- related contaminants under bulk and nanoconfined conditions. In that, we first established solid protocols to synthesize and fabricate numerous types of geocolloids with a. various sizes ranging from 40 – 800 nm and b. different hydrophile-lipophile balance (HLB) ratios in the range of 25:75 to 75:25. Direct force measurements with geocolloids having different degrees of surface coverages (i.e. HLB to realistically mimic adsorption of energy related contaminants) were conducted using the Surface Forces Apparatus (SFA) over a distance regime starting from 8μm all the way down to molecular contact. Repulsive forces were observed on approach starting from > 3μm, followed by an exponential increase of which magnitude appears to be larger than a decay length obtained from Derjaguin–Landau–Verwey–Overbeek (DLVO) theory in pure water. When the geocolloids were confined in salted water, the magnitude of onset of repulsion was varied as a function of salinity in solution, which can significantly alter a purely repulsive screened electrostatic (coulombic) interaction arising from, among geocolloids as well as between geocolloids and geosurfaces. The viscosity and flow characteristics of geocolloidal suspensions at different degrees of confinement were also investigated where we identified highly discontinuous rheological behaviors below a critical nanoconfinement level. We anticipate that the knowledge gained through this study will enable the scientists and researchers to better assess transport and fate behaviors of geocolloidal dispersions that can carry energy-related contaminants under realistically emulated geosystem.

03 NATURAL GAS↗
DOE OSTI2024

Cathodic Decomposition Electrodes as Standard Reference Electrodes for Molten Salts: Example of the Lithium Eutectic Electrode for the LiCl-KCl Eutectic

Alternatives to the widely-used standard anodic decomposition reference electrodes in molten salts are necessary to enable more easily reproduced thermochemical and electrochemical data in molten salt electrolytes. The class of standard reference electrodes called cathodic decomposition electrodes (CDEs) are easily constructed and can be used to make thermochemical measurements in molten salts more directly compared to anodic decomposition electrodes. The lithium eutectic electrode (LEE) was chosen as a sample test case for validation and was applied to thermochemical measurements of electroactive species in molten LiCl-KCl eutectic. Transient measurements were made to measure the Li + /Li reduction potential at zero current in pure LiCl-KCl eutectic relative to a Li-alloy reference electrode to validate the reference potential of the LEE. Literature-reported electromotive force measurements against Li-alloy reference electrodes were used to generate a relationship between the LEE and the standard chlorine electrode and this relationship was used to evaluate measured and reported formal potential measurements for the LiCl-KCl-GdCl 3 system. This work demonstrates the general framework for defining CDEs for any molten salt system and a method for calibrating external reference electrodes against a CDE standard reference electrode, improving the ease of obtaining thermochemical and electrochemical measurements in any molten salt system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Cation valency in water-in-salt electrolytes alters the short- and long-range structure of the electrical double layer

Highly concentrated aqueous electrolytes (termed water-in-salt electrolytes, WiSEs) at solid-liquid interfaces are ubiquitous in myriad applications including biological signaling, electrosynthesis, and energy storage. This interface, known as the electrical double layer (EDL), has a different structure in WiSEs than in dilute electrolytes. Here, we investigate how divalent salts [zinc bis(trifluoromethylsulfonyl)imide, Zn(TFSI) 2 ], as well as mixtures of mono- and divalent salts [lithium bis(trifluoromethylsulfonyl)imide (LiTFSI) mixed with Zn(TFSI) 2 ], affect the short- and long-range structure of the EDL under confinement using a multimodal combination of scattering, spectroscopy, and surface forces measurements. Raman spectroscopy of bulk electrolytes suggests that the cation is closely associated with the anion regardless of valency. Wide-angle X-ray scattering reveals that all bulk electrolytes form ion clusters; however, the clusters are suppressed with increasing concentration of the divalent ion. To probe the EDL under confinement, we use a Surface Forces Apparatus and demonstrate that the thickness of the adsorbed layer of ions at the interface grows with increasing divalent ion concentration. Multiple interfacial layers form following this adlayer; their thicknesses appear dependent on anion size, rather than cation. Importantly, all electrolytes exhibit very long electrostatic decay lengths that are insensitive to valency. It is likely that in the WiSE regime, electrostatic screening is mediated by the formation of ion clusters rather than individual well-solvated ions. This work contributes to understanding the structure and charge-neutralization mechanism in this class of electrolytes and the interfacial behavior of mixed-electrolyte systems encountered in electrochemistry and biology.

Science & Technology - Other Topics↗
DOE OSTI2024

Super-relaxed myosins contribute to respiratory muscle hibernation in mechanically ventilated patients

Patients receiving mechanical ventilation in the intensive care unit (ICU) frequently develop contractile weakness of the diaphragm. Consequently, they may experience difficulty weaning from mechanical ventilation, which increases mortality and poses a high economic burden. Because of a lack of knowledge regarding the molecular changes in the diaphragm, no treatment is currently available to improve diaphragm contractility. We compared diaphragm biopsies from ventilated ICU patients (N= 54) to those of non-ICU patients undergoing thoracic surgery (N= 27). By integrating data from myofiber force measurements, x-ray diffraction experiments, and biochemical assays with clinical data, we found that in myofibers isolated from the diaphragm of ventilated ICU patients, myosin is trapped in an energy-sparing, super-relaxed state, which impairs the binding of myosin to actin during diaphragm contraction. Studies on quadriceps biopsies of ICU patients and on the diaphragm of previously healthy mechanically ventilated rats suggested that the super-relaxed myosins are specific to the diaphragm and not a result of critical illness. Exposing slow- and fast-twitch myofibers isolated from the diaphragm biopsies to small-molecule compounds activating troponin restored contractile force in vitro. These findings support the continued development of drugs that target sarcomere proteins to increase the calcium sensitivity of myofibers for the treatment of ICU-acquired diaphragm weakness.

Cell Biology↗
DOE OSTI2024

Non-Reciprocity, Metastability, and Dynamic Reconfiguration in Co-Assembly of Active and Passive Particles

Living organisms often exhibit non-reciprocal interactions where the forces acting on the objects are not equal in magnitude or opposite in direction. The combination of reciprocal and non-reciprocal interactions between synthetic building blocks remains largely unexplored. Here, out-of-equilibrium assemblies of non-motile isotropic passive and metal-patched motile active particles are formed by overlapping bulk interactions with directed self-propulsion. An external alternating current (AC) electric field generates concurrent dipolar and induced-charge electrophoretic forces between the particles which are evaluated using microscopy. The interaction force measurements allow to determine the degree of reciprocity in interactions, which is tunable by designing the active particle and its trajectory. While linearly-propelled active particles evade assembly with passive particles, helically propelled active particles form active-passive clusters with dynamic reconfiguration and long-lived metastability. Large clusters display programmable fluctuations and reconfigurability by controlling the fraction of active particles. The study establishes principles of integrating reciprocal and non-reciprocal interactions in guided colloidal assembly of reconfigurable metastable structures.

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

Electrochemo-mechanics unlocks hidden dynamics of lithium plating under stacking pressure

Understanding and mitigating lithium plating remains one of the most pressing challenges in advancing the safety and longevity of lithium-ion batteries (LIBs). Here, we present a novel integrative framework that combines in-operando swelling force measurements with a physics-based electro-chemo-mechanical model to uncover previously inaccessible insights into lithium plating dynamics under mechanical constraints. Unlike existing approaches that focus primarily on electrochemical signatures, our approach captures the coupled mechanical responses of commercial pouch cells during cycling, revealing how mechanical constraints fundamentally alter degradation pathways. We demonstrate that the use of a moderate stacking pressure suppresses lithium plating and enhances lithium stripping. This mechanically driven structural effect, coupled with the electrochemical process, significantly extends the linear aging regime in LIBs. Intriguingly, intermittent capacity recovery events that were observed during the battery cycling suggest dynamic lithium reactivation, a phenomenon rarely captured in real-time. This study pioneers a stress-aware methodology for diagnosing and managing lithium plating, establishing a new paradigm for real-time battery health monitoring. The findings offer transformative implications for the design of durable, high-performance LIB systems, opening new avenues for intelligent control strategies in battery management systems.

Bhowmick, Amit↗
DOE OSTI2025

Legacy Survey of Space and Time Data Preview 1: dia_object_forced_source dataset type

The Legacy Survey of Space and Time Data Preview 1 (DP1) is the first release of data from the NSF-DOE Vera C. Rubin Observatory. It consists of raw and calibrated single-epoch images, co-adds, difference images, detection catalogs, and other derived data products. DP1 is based on 1792 science-grade optical/near-infrared exposures acquired over 48 distinct nights by the Rubin Commissioning Camera, LSSTComCam, on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile during the first on-sky commissioning campaign in late 2024. DP1 covers a total of approximately 15 sq. deg. over seven roughly equally-sized non-contiguous fields, each independently observed in six broad photometric bands, ugrizy, spanning a range of stellar densities and latitudes and overlapping with external reference datasets. This dataset is a subset of the full data release consisting of the dia_object_forced_source dataset type. These are forced measurements in visit and difference images, at the coordinates of all DIA objects. This release contains 597 datasets of this type.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Legacy Survey of Space and Time Data Preview 1: ForcedSourceOnDiaObject searchable catalog

The Legacy Survey of Space and Time Data Preview 1 (DP1) is the first release of data from the NSF-DOE Vera C. Rubin Observatory. It consists of raw and calibrated single-epoch images, co-adds, difference images, detection catalogs, and other derived data products. DP1 is based on 1792 science-grade optical/near-infrared exposures acquired over 48 distinct nights by the Rubin Commissioning Camera, LSSTComCam, on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile during the first on-sky commissioning campaign in late 2024. DP1 covers a total of approximately 15 sq. deg. over seven roughly equally-sized non-contiguous fields, each independently observed in six broad photometric bands, ugrizy, spanning a range of stellar densities and latitudes and overlapping with external reference datasets. This dataset is a subset of the full data release consisting of a searchable catalog named ForcedSourceOnDiaObject. This catalog contains forced measurements in visit and difference images, at the coordinates of all DIA objects. This catalog contains 196,911,566 rows with 28 columns.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Legacy Survey of Space and Time Data Preview 1: object_forced_source dataset type

The Legacy Survey of Space and Time Data Preview 1 (DP1) is the first release of data from the NSF-DOE Vera C. Rubin Observatory. It consists of raw and calibrated single-epoch images, co-adds, difference images, detection catalogs, and other derived data products. DP1 is based on 1792 science-grade optical/near-infrared exposures acquired over 48 distinct nights by the Rubin Commissioning Camera, LSSTComCam, on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile during the first on-sky commissioning campaign in late 2024. DP1 covers a total of approximately 15 sq. deg. over seven roughly equally-sized non-contiguous fields, each independently observed in six broad photometric bands, ugrizy, spanning a range of stellar densities and latitudes and overlapping with external reference datasets. This dataset is a subset of the full data release consisting of the object_forced_source dataset type. These are forced measurements in visit and difference images, at the coordinates of all objects. This release contains 636 datasets of this type.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Legacy Survey of Space and Time Data Preview 1: ForcedSource searchable catalog

The Legacy Survey of Space and Time Data Preview 1 (DP1) is the first release of data from the NSF-DOE Vera C. Rubin Observatory. It consists of raw and calibrated single-epoch images, co-adds, difference images, detection catalogs, and other derived data products. DP1 is based on 1792 science-grade optical/near-infrared exposures acquired over 48 distinct nights by the Rubin Commissioning Camera, LSSTComCam, on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile during the first on-sky commissioning campaign in late 2024. DP1 covers a total of approximately 15 sq. deg. over seven roughly equally-sized non-contiguous fields, each independently observed in six broad photometric bands, ugrizy, spanning a range of stellar densities and latitudes and overlapping with external reference datasets. This dataset is a subset of the full data release consisting of a searchable catalog named ForcedSource. This catalog contains forced measurements in visit and difference images, at the coordinates of all objects. This catalog contains 268,796,943 rows with 28 columns.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Legacy Survey of Space and Time Data Preview 2: dia_object_forced_source dataset type

We present Rubin Data Preview 2 (DP2), the second data preview from the NDF-DOE Vera C. Rubin Observatory. Data Preview 2 (DP2) comprises coadds, detection catalogs, and ancillary data products; and when fully released will also include single-epoch images and difference images. DP2 is derived from observations acquired by the LSST Science Camera (LSSTCam) on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile, primarily during the on-sky commissioning campaign between 2025-04-16 and 2025-09-21, supplemented by observations taken between 2025-10-25 and 2026-01-06 that overlap the commissioning footprint. The DP2 footprint comprises the Science Validation wide-area survey, five Deep Drilling Fields, and a number of targeted small-field regions, including Trifid and Lagoon, Prawn, M49, and New Horizons, all observed as part of the Rubin First Look campaign. Each field was imaged in up to six broad photometric bands, ugrizy, and coadded to produce deep imaging covering an estimated 3,000 deg2. The addition of single-visit-only areas expands the total DP2 footprint to an estimated 15,000 deg2, with coverage in at least one filter. The median per-visit PSF FWHM across the wide-area survey ranges from 1.17 arcsec in the z band to 1.26 arcsec in g and r bands. The deepest field, reaches estimated coadded 5σ depths of u=26 mag, g=26.8 mag, r=26.3 mag, i=26.1 mag, z=25.3 mag, y=23.9 mag. Based on a roughly five-month primary observing baseline and covering only part of the eventual LSST footprint, DP2's area, depth, and multiband coverage nonetheless support a broad range of early science investigations ahead of LSST Data Release This dataset is a subset of the full data release consisting of the dia_object_forced_source dataset type. These are forced measurements in visit and difference images, at the coordinates of all DIA objects. This release contains 183,169 datasets of this type.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Legacy Survey of Space and Time Data Preview 2: ForcedSourceOnDiaObject searchable catalog

We present Rubin Data Preview 2 (DP2), the second data preview from the NDF-DOE Vera C. Rubin Observatory. Data Preview 2 (DP2) comprises coadds, detection catalogs, and ancillary data products; and when fully released will also include single-epoch images and difference images. DP2 is derived from observations acquired by the LSST Science Camera (LSSTCam) on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile, primarily during the on-sky commissioning campaign between 2025-04-16 and 2025-09-21, supplemented by observations taken between 2025-10-25 and 2026-01-06 that overlap the commissioning footprint. The DP2 footprint comprises the Science Validation wide-area survey, five Deep Drilling Fields, and a number of targeted small-field regions, including Trifid and Lagoon, Prawn, M49, and New Horizons, all observed as part of the Rubin First Look campaign. Each field was imaged in up to six broad photometric bands, ugrizy, and coadded to produce deep imaging covering an estimated 3,000 deg2. The addition of single-visit-only areas expands the total DP2 footprint to an estimated 15,000 deg2, with coverage in at least one filter. The median per-visit PSF FWHM across the wide-area survey ranges from 1.17 arcsec in the z band to 1.26 arcsec in g and r bands. The deepest field, reaches estimated coadded 5σ depths of u=26 mag, g=26.8 mag, r=26.3 mag, i=26.1 mag, z=25.3 mag, y=23.9 mag. Based on a roughly five-month primary observing baseline and covering only part of the eventual LSST footprint, DP2's area, depth, and multiband coverage nonetheless support a broad range of early science investigations ahead of LSST Data Release This dataset is a subset of the full data release consisting of a searchable catalog named ForcedSourceOnDiaObject. This catalog contains forced measurements in visit and difference images, at the coordinates of all DIA objects. This catalog contains 24,259,599,059 rows with 26 columns.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Legacy Survey of Space and Time Data Preview 2: object_forced_source dataset type

We present Rubin Data Preview 2 (DP2), the second data preview from the NDF-DOE Vera C. Rubin Observatory. Data Preview 2 (DP2) comprises coadds, detection catalogs, and ancillary data products; and when fully released will also include single-epoch images and difference images. DP2 is derived from observations acquired by the LSST Science Camera (LSSTCam) on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile, primarily during the on-sky commissioning campaign between 2025-04-16 and 2025-09-21, supplemented by observations taken between 2025-10-25 and 2026-01-06 that overlap the commissioning footprint. The DP2 footprint comprises the Science Validation wide-area survey, five Deep Drilling Fields, and a number of targeted small-field regions, including Trifid and Lagoon, Prawn, M49, and New Horizons, all observed as part of the Rubin First Look campaign. Each field was imaged in up to six broad photometric bands, ugrizy, and coadded to produce deep imaging covering an estimated 3,000 deg2. The addition of single-visit-only areas expands the total DP2 footprint to an estimated 15,000 deg2, with coverage in at least one filter. The median per-visit PSF FWHM across the wide-area survey ranges from 1.17 arcsec in the z band to 1.26 arcsec in g and r bands. The deepest field, reaches estimated coadded 5σ depths of u=26 mag, g=26.8 mag, r=26.3 mag, i=26.1 mag, z=25.3 mag, y=23.9 mag. Based on a roughly five-month primary observing baseline and covering only part of the eventual LSST footprint, DP2's area, depth, and multiband coverage nonetheless support a broad range of early science investigations ahead of LSST Data Release This dataset is a subset of the full data release consisting of the object_forced_source dataset type. These are forced measurements in visit and difference images, at the coordinates of all objects. This release contains 192,147 datasets of this type.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Legacy Survey of Space and Time Data Preview 2: ForcedSource searchable catalog

We present Rubin Data Preview 2 (DP2), the second data preview from the NDF-DOE Vera C. Rubin Observatory. Data Preview 2 (DP2) comprises coadds, detection catalogs, and ancillary data products; and when fully released will also include single-epoch images and difference images. DP2 is derived from observations acquired by the LSST Science Camera (LSSTCam) on the Simonyi Survey Telescope at the Summit Facility on Cerro Pachón, Chile, primarily during the on-sky commissioning campaign between 2025-04-16 and 2025-09-21, supplemented by observations taken between 2025-10-25 and 2026-01-06 that overlap the commissioning footprint. The DP2 footprint comprises the Science Validation wide-area survey, five Deep Drilling Fields, and a number of targeted small-field regions, including Trifid and Lagoon, Prawn, M49, and New Horizons, all observed as part of the Rubin First Look campaign. Each field was imaged in up to six broad photometric bands, ugrizy, and coadded to produce deep imaging covering an estimated 3,000 deg2. The addition of single-visit-only areas expands the total DP2 footprint to an estimated 15,000 deg2, with coverage in at least one filter. The median per-visit PSF FWHM across the wide-area survey ranges from 1.17 arcsec in the z band to 1.26 arcsec in g and r bands. The deepest field, reaches estimated coadded 5σ depths of u=26 mag, g=26.8 mag, r=26.3 mag, i=26.1 mag, z=25.3 mag, y=23.9 mag. Based on a roughly five-month primary observing baseline and covering only part of the eventual LSST footprint, DP2's area, depth, and multiband coverage nonetheless support a broad range of early science investigations ahead of LSST Data Release This dataset is a subset of the full data release consisting of a searchable catalog named ForcedSource. This catalog contains forced measurements in visit and difference images, at the coordinates of all objects. This catalog contains 44,727,948,693 rows with 28 columns.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Control of machining-induced residual stress via tool geometry and process parameter modification

Distortion generated in machined, monolithic, thin-walled aerospace components due to residual stresses leads to significant material and economic waste in the manufacturing industry. Inherent residual stress (IRS) present in stock materials combines with machining-induced residual stress (MIRS) to influence the final machined part distortion. It is hypothesized that MIRS can be controlled, based on the part geometry, through deliberate cutting tool geometry and process parameter modifications to negate the effect of IRS on distortion, consequently resulting in distortion-free parts. A finite element (FE) orthogonal cutting model is developed to study how tool geometry and process parameters influence machining-induced residual stress (MIRS). Orthogonal cutting experiments are performed on Al 7075-T651 samples to measure cutting forces and MIRS. A cutting force dynamometer is used to measure forces during cutting and a novel digital image correlation (DIC) based hole drilling technique is employed to measure the near-surface residual stress (RS) in the cut samples. These data are subsequently utilized to validate the FE prediction model. Various cases of cutting simulations involving different depths of cut, tool tip radii, and rake angles are performed to study their effects on RS. Similar to prior literature, increasing the depth of cut, tool tip radius, or rake angle is found to promote the formation of near-surface tensile stresses. The competing effects of material plowing and temperature are shown to determine the type of RS at the end of the cut. Moreover, a window of variation of RS (up to ± 400 MPa) is estimated within the given range of conditions, allowing for the control of MIRS through tool and process modification.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗