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All sources NASA NTRS DOE OSTI

DOE OSTI2022

Explanation and Application of the Evolving Contact Traction Fields in Shallow Foundation Systems

The present paper provides a qualitative discussion of the evolution of contact traction fields beneath rigid shallow foundations resting on granular materials. A phenomenological similarity is recognized in the measured contact traction fields of rigid footings and at the bases of sandpiles. This observation leads to the hypothesis that the stress distributions are brought about by the same physical phenomena, namely the development of arching effects through force chains and mobilized intergranular friction. A set of semi-empirical equations are suggested for the normal and tangential components of this contact traction based on past experimental measurements and phenomenological assumptions of frictional behaviors at the foundation system scale. These equations are then applied to the prescribed boundary conditions for the analysis of the settlement, resistance, and stress fields in supporting granular materials beneath the footing. A parametric sensitivity study is performed on the proposed modelling method, highlighting solutions to the boundary-value problems in an isotropic, homogeneous elastic half-space.

42 ENGINEERING↗

DOE OSTI2022

Elastic Solutions to 2D Plane Strain Problems: Nonlinear Contact and Settlement Analysis for Shallow Foundations

The classical Neumann boundary value problem of an isotropic, homogeneous elastic half-plane under plane strain conditions is readdressed as the limiting case of the fully three-dimensional problem. Analytical solutions of the stress and strain tensors are obtained by taking the limit from known three-dimensional solutions. It is shown that the displacement fields for the plane strain problem are not well defined. A small number of simple expressions are developed, which provide a general solution for linearly-varying traction over arbitrary regions on the boundary. A simple, efficient, and rapidly convergent algorithm is developed which uses these solutions as analytic elements and provides a solution approach to the general boundary value problem. The method is verified against known solutions for Hertzian contact between parallel cylinders. Two numerical examples are presented for the analysis of shallow foundation systems. In the first, the boundary conditions are informed by analytical elastoplastic calculations and a strain influence analysis is performed and compared with the Schmertmann method. Subsequently, empirical laboratory contact traction distributions measured by Bauer et al., in both the normal and tangential directions are employed as boundary conditions for an analysis of the underlying stress field.

42 ENGINEERING↗

NASA NTRS1966

On the stability of shallow cylindrical shells supported on the inner surface by an elastic foundation

Characteristic buckling features of elongated cylindrical shell supported on inner surface by elastic foundation

SHALLOW SHELL EQUATION↗

NASA NTRS2001

Evaluation of Instability Phenomena in Sands: Plane Strain Versus Triaxial Conditions

Extensive research was carried out in the 1950s on theories of plasticity to extend the concepts developed for metals to materials that failed according to the Mohr-Coulomb criterion. The new ideas made it possible to merge the two distinct concepts (strength and deformation techniques) into one that relies on better understanding of plasticity and resulted in a rapid growth in the field of constitutive modeling of soil behavior. At the same time advanced experimental apparatuses and laboratory procedures were developed to calibrate the models. However, most laboratory experiments on granular materials are performed under Conventional Triaxial Conditions (CTC) for the purposes of evaluating constitutive behavior and stability properties, whereas most geotechnical field problems are closer to the Plane Strain (PS) condition. The triaxial tests performed in most laboratories comprise a simplification over in situ states and allow easier and robust experimentation. Most landslide problems, failure of soils beneath shallow and deep foundations, and failure of retaining structures, are cases that can generally be considered as plane strain. Strength and deformation characteristics of granular materials loaded in plane strain may be considerably different from those observed in CTC. Most studies on sands were limited to evaluating the constitutive behavior and in some cases extended to briefly describing the associated instability phenomena. This paper presents the results of a series of PS and CTC experiments performed on fine uniform silica sand known as F-75 Ottawa sand. Advanced analysis techniques were used to study the instability phenomena, which yielded very accurate measurements of shear bands occurrences and patterns. Destructive thin-sectioning technique along with monitoring the specimen surface deformation was used in the PS experiments and Computed Tomography (CT) was used to investigate the progress of primary and secondary shear bands in specimens subjected to CTC. Comparison between the two cases will be presented and discussed.

Alshibli, Khalid A.↗

NASA NTRS1992

Laboratory evaluation of footings for lunar telescopes

Presented here are the results of laboratory experiments with diffferent footing shapes for lunar telescopes. These experiments used a variety of soils including some to simulate regolith response. Based on what is known of regolith and regolith-structure interaction, a shallow-multiple-contact points footing foundation can be adequately designed to support lunar telescopes. Plane-strain load-displacement tests were conducted with different footings and different lunar simulants in a deep transparent plexiglass container. The model footings considered include the rectangular, hemispherical, and spudcan designs. Simulants used to reproduce the mechanical properties of the lunar regolith were fly ash, crushed basalt with and without glass, and a processed lunar simulant. Load-displacement curves were obtained for the different footings in Ottawa sand and in the crushed basalt with glass. The spudcan footing was found to be self-digging and yet stiff, thus providing excellent lateral stability in a large variety of soils.

Chua, Koon M.↗

DOE OSTI2021

Thermal stress reduces carbonate production of benthic foraminifera and changes the material properties of their shells

Abstract In shallow marine environments, benthic foraminifera are important foundation species and carbonate producers. Understanding their response to future climate is often drawn from their acclimation potential in short laboratory experiments, thereby limiting our understanding of migration, species replacement, and adaptive potential. To overcome this challenge, we examine two species of benthic foraminifera from a thermally polluted field site mimicking future warming. This site and a control station cover 13–36°C causing both warm and cold stress to the local species. Computer Tomography reveals that under heat stress, even with acclimation, Lachlanella significantly reduced its shell volume. In contrast, Pararotalia calcariformata did not reduce its shell volume but reduced the relative amount of calcite with respect to shell volume and changed its reproduction cycle from twice to once per year. Raman spectroscopy indicates that thermal conditions alter the chemical composition of the calcite shells of both species. Calcification during thermal stress creates alterations in the crystal structure that are unexpectedly more prominent under cold stress than warm stress indicating warming might positively affect the shell's protective function. Supported by previous laboratory experiments and observations from the geological record, our results provide new perspective to the effect of warming on benthic foraminifera.

Titelboim, Danna↗

DOE OSTI2023

Ecosystems and Networks Integrated with Genes and Molecular Assemblies (Final Scientific/Technical Report)

The ENIGMA science focus area (SFA) is a multi-disciplinary, multi-institutional research effort focused on addressing foundational knowledge gaps in environmental microbial communities by studying groundwater and sediment microbiomes in the shallow subsurface at the contaminated Oak Ridge Field Research Site (FRC). We seek to discover and characterize the reciprocal interactions between the microbial communities and the geochemical and geophysical parameters of the shallow subsurface within the contamination plume. The goal of the Fields lab is to help manage and conduct laboratory experiments informed by field observations using ecological and physiological approaches to study microbial populations in situ as well as ex situ (in the laboratory). In particular, we aim to study and characterize the impact of hydrological constraints on free-living and biofilm biomass and activity with increasing spatial and temporal resolution under static and flow conditions. We also aim to help characterize novel microbial groups that are present and active under relevant field conditions, including the development of molecular techniques for in situ detection as well as metabolic interactions that underlie pertinent physiology and ecology.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2024

Ecosystems and Networks Integrated with Genes and Molecular Assemblies (ENIGMA): Molecular and Computational Technologies for Environmental Microbiology (Final Scientific/Technical Report)

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Universality of Shallow Global Quenches in Critical Spin Chains

Measuring universal data in the strongly correlated regime of quantum critical points remains a fundamental objective for quantum simulators. In foundational work, Calabrese and Cardy demonstrated how these data govern the dynamics of certain global quenches to 1+1-dimensional conformal field theories. While the quasiparticle picture they introduce has been widely successful in both theory and experiment, their seminal prediction that the critical exponents are simply encoded in the relaxation rates of local observables is challenging to investigate experimentally. In this Letter, we examine the critical quench dynamics of local observables from two types of readily accessible initial conditions: ground states and finite-temperature ensembles. Here, we identify universal scaling collapses and scaling functions, utilizing a combination of conformal perturbation theory and tensor network numerics. For the finite-temperature quenches, we determine a regime in which the conformal field theory results are recovered, thereby allowing universal quantum critical data to be extracted from realistic quenches.

Quantum many-body systems↗

DOE OSTI2023

Grounding our Understanding of the Impacts of Boreal Forest Expansion on Shallow Cumulus Clouds with a Simple Modeling Framework

Abstract The expansion of the boreal forest poleward is a potentially important driver of feedbacks between the land surface and Arctic climate. A growing body of work has highlighted the importance of differences in evaporative resistance between different possible future Arctic land covers, which in turn alters humidity and cloudiness in the boundary layer, for these feedbacks. While thus far this problem has been studied primarily with complex Earth system models, we turn to a locally focused, idealized model capable of diagnosing and testing the sensitivity of first-order processes connecting vegetation, the atmospheric boundary layer, and low clouds in this critical region. This allows us to benchmark the mechanisms and results at the center of predictions from larger-scale simulations. A surface dominated by broadleaf trees, characterized by higher albedo and lower surface evaporative resistance, drives cooling and moistening of the boundary layer relative to a surface of needleleaf trees, characterized by lower albedo and higher surface evaporative resistance. Differences in evaporative resistance between these hypothetical Arctic vegetation covers are of equal importance to changes in albedo for the initial response of the boundary layer to boreal expansion, even with our idealized approach. However, compensation between the elevation of the lifting condensation level (LCL) and more rapid growth of the mixed layer over higher evaporative resistance surfaces can minimize changes in the favorability of shallow clouds over different land cover types under some conditions. We then perform two tests on the sensitivity of this compensating effect, to changes in water availability, represented first by a reduction in boundary layer humidity and then by both a reduction in humidity and soil moisture available to our vegetation surface. Finally, given the importance of this potential LCL–mixed-layer height compensation in our idealized modeling results, we look to determine its relevance in observational data from a field campaign in boreal Finland. These observations do confirm that such a coupling plays an important role in cumulus-topped boundary layers over a needleleaf forest surface. While our results confirm some underlying mechanisms at the center of prior work with Earth system models, they also provide motivation for future work to constrain the impact of boreal forest expansion. This will include both large eddy simulations to examine the impact of processes and feedbacks not resolved by a mixed-layer model, as well as a more systematic evaluation and comparison of relevant observations at the site in Finland and sites from prior boreal field campaigns. Significance Statement Clouds and vegetation are both important components of the climate system that interact across a range of scales. These interactions are central to understanding how changes at the land surface feedback on climate. For example, if a forest expands or recedes, diagnosing how that will impact clouds will determine whether you predict warming or cooling temperatures from that shift in the forest area. These predictions are often made with complex Earth system models, but we look to a more idealized representation of the land–atmosphere system to diagnose how shallow clouds should respond to changes in surface properties with different scenarios of boreal forest expansion at a more foundational level. This both grounds our understanding of previous analysis and provides helpful direction for future studies of this relevant and impactful land cover change.

Meteorology & Atmospheric Sciences↗

NASA NTRS2010

Epistemic Questions and Answers for Software System Safety

System safety is primarily concerned with epistemic questions, that is, questions concerning knowledge and the degree of confidence that can be placed in that knowledge. For systems with which human experience is long, such as roads, bridges, and mechanical devices, knowledge about what is required to make the systems safe is deep and detailed. High confidence can be placed in the validity of that knowledge. For other systems, however, with which human experience is comparatively short, such as those that rely in part or in whole on software, knowledge about what is required to ensure safety tends to be shallow and general. The confidence that can be placed in the validity of that knowledge is consequently low. In a previous paper, we enumerated a collection of foundational epistemic questions concerning software system safety. In this paper, we review and refine the questions, discuss some difficulties that attend to answering the questions today, and speculate on possible research to improve the situation.

Holloway, C. M.↗

NASA NTRS2003

Records of our Early Biosphere Illuminate our Origins and Guide our Search for Life Beyond Earth

A scientific "mission of exploration to early Earth" will help us chart the distribution of life elsewhere. We must discriminate between attributes of biospheres that are universal versus those attributes that represent principally the outcomes of long-term survival specifically on Earth. In addition to the basic physics and chemistry of matter, the geologic evolution of rocky habitable planets and their climates might be similar elsewhere in the Universe. Certain key agents that drive long-term environmental change (e.g., stellar evolution, impacts, geothermal heat flow, tectonics, etc.) can help us to reconstruct ancient climates and to compare their evolution among populations of Earth- like planets. Early Earth was tectonically more active than today and therefore it exhaled reduced chemical species into the more oxidized surface environment at greater rates. This tectonic activity thus sustained oxidation-reduction reactions that provided the basis for the development of biochemical pathways that harvest chemical energy ("bioenergetics"). Most examples of bioenergetics today that extract energy by reacting oxidized and reduced chemicals in the environment were likely more pervasive among our microbial ancestors than are the presently known examples of photosynthesis. The geologic rock record indicates that, as early as 3.5 billion years ago (3.5 Ga), microbial biofilms were widespread within the coastal environments of small continents and tectonically unstable volcanic islands. Non oxygen-producing (non-oxygenic) photosynthesis preceded oxygenic photosynthesis, but all types of photosynthesis contributed substantially to the long-term increase in global primary biological productivity. Evidence of photosynthesis is tentative by 3.5 Ga and compelling by 2.7 Ga. Evidence of oxygenic photosynthesis is strong by 2.7 Ga and compelling by 2.3 Ga. These successive innovations transformed life from local communities that survived principally by catalyzing chemical equilibration to a globally dominant agent that created and sustained widespread chemical disequilibria in the environment and shallow crust. Major biogeochemical perturbations ca. 2.3 to 2.0 Ga, 1.3 Ga, and also 0.8 to 0.6 Ga, contributed to the irreversible oxidation of the global environment and perhaps also triggered evolutionary innovations (e.g., the development of multi-cellular biota) that became the foundations of our modern biosphere. Understanding the nature and timing of this ascent of life is crucial for discerning our o m beginnings. This understanding also empowers OUT search for the origins, evolution and distribution of life elsewhere in our solar system and beyond.

DesMarais, David J.↗

DOE OSTI2023

Robust In-Situ Strain Measurements to Monitor CO 2 Storage

The goal of this project was to develop and demonstrate robust instrumentation to monitor the in-situ strain tensor in order to improve the reliability and security of CO 2 storage in geologic formations. We met the original goals of the project and the major overarching accomplishment is the advancement of strain tensor monitoring from an intriguing concept to a commercially available technology with a solid foundation of novel instruments supported by theoretical analyses and validation experiments. The main accomplishments of the project are summarized below. We designed, built and evaluated nine new optical fiber strainmeters and tiltmeters using Michelson interferometers to measure deformation with ultra-high resolution at both shallow and deep point locations in the subsurface. These are the robust strainmeters that motivated the title of the project. We designed, built and evaluated a novel method of measuring distributed strain in optical fibers with nanostrain resolution, and cm-scale location, and sampling into the seismic band. The new method is called Coherence-length-gated Microwave Photonics Interfereometry (CMPI). CMPI technology has advantages over existing commercial DAS and DSS methods. We developed and demonstrated capabilities to deploy instruments in the field and used them to measure strain caused by ambient signals like barometric pressure and tides, as well as induced signals like surface loading and pore pressure changes from pumping tests. We deployed a working strainmeter at 1,700 ft depth, slightly above an active reservoir. This is to our knowledge the greatest depth a strainmeter has been deployed and the techniques we used can readily be extended to greater depths. Optical fiber borehole tensor strainmeter techology was advanced from a TRL 4 at the start, to a TRL of 7 at the conclusion of the project. The project included advances in simulations and theoretical analyses. We developed and demonstrated a computational workflow that uses machine learning to reduce the computational requirements and make it practical to use Bayesian inversion to solve large numerical poroelastic analyses needed to interpret strain tensor field data. We evaluated the strain tensor fields and time series that would be caused by leaks of CO 2 or other fluids from reservoirs. These simulations demonstrated that signals from leaks could be measured with instruments developed for the project, opening a potentially new method for ensuring storage security. We showed that strains in caprock can be used to estimate pressure in a reservoir. This avoids the need to drill monitoring wells into the reservoir, and it expands the capabilities of monitoring in the caprock. The project includes a derivation and application of a novel analytical solution to the strains in the vicinity of a pressurized poroelastic inclusion. This solution explains field data measured during injeciton tests at the North Avant Field, and it will simplify future interpretation of strain tensor data. The project included a broad range of experiments, and of the most significant is the characterization of the strain tensor at an array three strainmeters during six injection tests at the North Avant Field, Oklahoma. This demonstrated repeatability of the strain signal measured by the new instruments developed for the project, and it showed similarities between the strain signal at shallow depths and pressure in the underlying reservoir. We also demonstrated that useful strain data can be measured at reservoir depths. This confirms that strain tensor data can be measured throughout the caprock over a reservoir. The project demonstrated the feasibility of using the strain tensor and distributed strain measured in caprock during a variety of different well tests where the pumping rate was constant, sinusoidal and positive, or a periodic square wave with zero net rate. This further strengthens the validity of using strain data to characterize reservoirs and aquifers. We also demonstrated that strain caused be fluctuations of air pressure and water pressure in the vadose zone can be measured and interpreted, suggesting that high resolution distributed strain measurements hold promise for monitoring the vadose zone. The project partially supported nine graduate students in the Environmental Engineering, Hydrogeology, Electrical Engineering programs at Clemson University. The research was described in nine journal papers, 23 talks and conference abstracts. Additional journal papers are in preparation. A new company called Tensora was started to provide strainmeter technology for commercial applications.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

Local time stepping for the shallow water equations in MPAS

In this work we assess the performance of a set of local time-stepping (LTS) schemes for the shallow water equations implemented in the Model for Prediction Across Scales (MPAS). The goal of LTS is to speed up the simulation by allowing different time-steps on different regions of the computational grid. The LTS schemes considered here were originally introduced by Hoang et al. (2019) [26], who laid out the mathematical foundation of the methods. Here, the authors take on the task of presenting a fast, efficient and scalable parallel implementation of these LTS methods on high performance computing machines, with the aim to provide a recipe for other climate modeling groups that may be interested in employing LTS algorithms in their codes. As a matter of fact, even if MPAS is our framework of choice, our approach is general enough and could be of interest to other groups beyond the MPAS community. Due to their nature, LTS methods possess an inherent load imbalance that needs to be carefully addressed in order to obtain efficient scalability. Even more important is the far from trivial task of computing the right-hand side terms only on specific LTS regions during the time-stepping procedure. An inefficient handling of this task causes a drastic decay of the CPU time performance, making the LTS algorithms practically of no use. The emphasis of the present work is therefore on the computational and parallel aspects of the LTS methods, whose proper treatment is crucial to make the methods run faster against existing strategies, such as for instance high-order explicit global time-stepping schemes. This is in fact the ultimate goal of using an LTS procedure and it is the one to which we direct all our optimization efforts.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

2.2.1.410 - Significant Cost Reduction Potential for Wave Energy Conversion Devices with Variable-Geometry Modules

The Technology Commercialization Fund (TCF) award is built upon NREL's previous research exploring a bottom-fixed variable-geometry oscillating surge wave energy converter (VGOSWEC); however, unlike previous investigations, the VGOSWEC will be raised off the sea floor. Researchers believe that advances in offshore pilings and foundations, such as 3D printing, will provide low cost and easily deployable structures. There are several benefits to designing a raised VGOSWEC such as 1) reducing issues with sediment transport and environmental impacts near shore, 2) less expensive deployment and installation as work boats will not risk grounding in shallow water, and 3) deeper water deployments improve the wave resource.

oscillating surge wave energy converter↗

DOE OSTI2024

Mechanical and Thermal Forcing for Upslope Flows and Cumulus Convection over the Sierras de Córdoba

Abstract The upslope flow processes affecting the vertical extent of orographic cumulus convection are examined using observations from the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) field campaign. Specifically, clear air returns from the U.S. Department of Energy (DOE) second-generation C-band scanning Atmospheric Radiation Measurement (ARM) precipitation radar (CSAPR2) are used to characterize the structure and variability of the ridge-normal (i.e., up/downslope) flow components, which transport mass to the crest of Argentina’s Sierras de Córdoba and contribute to convective initiation. Data are compiled for the entire CACTI period (October–April), including days with clear skies, shallow cumuli, cumulus congestus, and deep convection. To examine shared variability among >70 000 radar scans, we use (i) a principal component analysis (PCA) to isolate modes of variability in the upslope flow and (ii) composite analysis based on convective outcomes, determined from GOES-16 satellite observations. These data are contextualized with observed surface sensible heat fluxes, thermodynamic profiles, and synoptic-scale analysis. Results indicate distinct thermally and mechanically forced upslope flow modes, modulated by diurnal heating and synoptic-scale variations, respectively. In some instances, there is a superposition of thermal and mechanical forcing, yielding either deeper or shallower upslope flow. The composite analyses based on satellite data show that successively deeper convective outcomes are associated with successively deeper upslope flow layers that more readily transport mass to the ridge crest in conjunction with lower lifting condensation levels, facilitating convective initiation. These results help to isolate the forcing mechanisms for orographic convection and thus provide a foundation for parameterizing orographic convective processes in coarse resolution models.

Meteorology & Atmospheric Sciences↗

DOE OSTI2025

STILGAR End-of-Project Report

The Subsurface Tunnel Imaging LeveraGed by Analysis of Rayleigh wave ellipticity (STILGAR) project demonstrated an integrated geophysical approach for detecting, locating, and characterizing underground structural changes using dense seismic arrays and advanced inversion techniques. Field campaigns were conducted at two operational mines—the Redmond salt mine (Utah) and Graymont Pleasant Gap limestone mine (Pennsylvania)—providing real-world testbeds for monitoring anthropogenic subsurface activity. At the Redmond salt mine, seismic interferometry combined with back-projection inversion successfully identified continuous, low-amplitude signals from mining operations. The approach differentiated stationary from migrating anthropogenic sources, captured daily operational cycles, and validated the potential of passive seismic monitoring for remote detection of underground activity. At the Graymont Pleasant Gap mine, two dense seismic deployments in the spring and fall of 2023 generated over 4 TB of high-resolution data. Key outcomes included the relocation of 199 underground and 8 surface explosions with accuracies within tens of meters and the development of a 3D P-wave velocity model using the triple-difference tomography algorithm (tomoTD) that resolved major structural features such as the mine entrance, low-velocity tunnels, and roof-collapse areas. Ambient noise cross-correlation and back-projection analyses revealed persistent sources linked to ongoing mining activity, whereas horizontal-to-vertical spectral ratio (HVSR) and ellipticity studies confirmed stable site responses across seasons and identified soil thickness trends consistent with regional erosional and depositional processes. Checkerboard and sensitivity tests further validated the robustness of the tomographic results. Overall, the findings emphasize that although significant progress has been made in subsurface imaging, further work is needed to enhance the detection and localization of underground structures. Accurate imaging requires higher frequencies, yet anthropogenic sources tend to dominate the seismic record at those frequencies, and high-frequency surface waves are affected by higher modes that complicate interpretation. The improved detection and localization of human-induced signals enabled detailed temporal and spatial mapping of daily mine operations, demonstrating the feasibility of continuous anthropogenic source monitoring. Sensitivity to signals from nontraditional sources, such as fan operations, highlights the broader applicability of this approach to other industrial environments in which continuous and impulsive signals are present. The field campaigns produced a substantial volume of high-quality seismic data, supporting the development and testing of new methods for seismic source characterization and subsurface imaging. Future deployments should include sensors capable of recording lower frequencies to probe deeper structures, increase bandwidth to enhance resolution and sensitivity to both shallow and deep targets, and collect additional large-scale datasets to refine imaging and source characterization techniques. Moreover, conducting 3D modeling studies of seismic wavefields at higher frequencies will provide a better understanding of wave scattering and cavity–wavefield interactions in complex underground environments. In conclusion, the STILGAR project demonstrated that integrated seismic monitoring can effectively characterize underground operations, capturing both natural and anthropogenic signals. The approaches developed provide a foundation for improved detection, localization, and imaging of subsurface structures and are directly transferable to broader industrial monitoring applications.

58 GEOSCIENCES↗

DOE OSTI2025

Experimental Comparison of Elastomeric Materials for Hydraulic Seal Durability under Reciprocating Conditions

Wave Energy Converters (WECs) rely on hydraulic Power Take-Off (PTO) systems to transform the kinetic energy of ocean waves into electricity, where hydraulic seals play a critical role in preventing fluid leakage and ensuring watertight operation under harsh marine conditions. However, seal degradation due to wear, fatigue, and corrosion remains a key challenge limiting system reliability and increasing maintenance costs. In this study, the tribological performance of elastomeric materials for hydraulic sealing applications that are based on commercial polyurethane and custom-compounded Ethylene Propylene Diene Monomer (EPDM) is investigated. Using a CSM tribometer, reciprocating wear tests were conducted in accordance with ASTM G133 under dry sliding conditions, with normal loads ranging from 3 to 10 N, and sliding speeds of 10 to 30 mm/s. Coefficient of friction (COF), specific wear rate, and worn surface morphology are evaluated to understand how load, velocity, and material composition affect seal durability. Improved wear stability and high Shore A hardness (93–94) were demonstrated by the commercial thermoplastic polyurethane (Duralast 4203 and 4758). EPDM-based compounds showed different filler-dependent behaviors, formulations filled with carbon black (E3) had the lowest wear rate (1.45 × 10?4 mm³ N?¹ m?¹) and increased load-bearing capacity, while samples modified with silica and plasticizer (E4, E5) had better conformability and damping but less hardness. Compounded EPDMs showed wider deformation zones because of their lower modulus and filler-matrix interfacial fluctuations, while commercial grades exhibited shallower wear scars (= 380 µm), according to optical profilometry. The Archard model-based lifetime estimation showed that, under 10 N and 30 mm/s, operational endurance ranged from 3.1 to 6.2 years. Because of its low wear rate and steady interfacial behavior, E3 had the longest anticipated life. For medium-load hydraulic sealing applications, these results demonstrate the possibility of customized EPDM formulations as affordable substitutes for commercial polyurethanes. They also offer a quantitative foundation for material selection and lifespan prediction.

Durability↗