Accelerating and Enhancing Thermodynamic Simulations of Electrochemical Interfaces
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Chemistry↗
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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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MFIX-Exa: CFD-DEM Simulations of Thermodynamics and Chemical Reactions in Multiphase Flows
For presentation at the AIChE Annual Meeting, Orlando, FL, November 5-10, 2023.
Porcu, Roberto↗
Synchrotron X-ray diffraction analysis of constituent phases in transition joint between nickel alloy 738LC and a MnFeCoNiCu alloy
Synchrotron x-ray diffraction (XRD) analysis was performed on transition joints between a single-phase MnFeCoNiCu alloy and Ni-base Alloy 738LC to efficiently identify the constituent phases across the interface, with different levels of material intermixing generated by laser-welding with variable power. Here, the intermixing extent was quantified by postmortem energy dispersive x-ray spectroscopy mapping. Diffraction-based analyses on complex composition spaces with limited prior data present significant challenges because elemental substitution in both disordered and ordered phases is more extensive than in conventional alloy spaces, which may effectuate relatively large shifts in the observed lattice parameters that convolute the analysis. Therefore, thermodynamic simulations and crystallographic literature data were employed to construct a system-specific diffraction library of twelve prospective phases for the composition space investigated. Subsequently, for predicted disordered cubic phases, statistical hard-sphere models were established to estimate the lattice parameters and predict diffraction peak positions for inclusion in the library. The library was then employed to analyze diffraction profiles measured from the variably intermixed transition joints, with focus on accounting for both high and low-intensity peaks. 99.0 % of diffraction peaks with relative intensity greater than 0.001 were assigned to phases from the system-specific library, exemplifying rigorous peak accounting and indicating that no unexpected phases were present. Up to six of the twelve library phases were experimentally found in the transition joints. The lattice parameters predicted by the statistical hard-sphere model based upon thermodynamic simulations agree reasonably well with the measured values for the disordered FCC matrix phase.
36 MATERIALS SCIENCE↗
Physical-chemical-mechanical quantitative assessment of the microstructural evolution in Portland-limestone cement pastes exposed to magnesium sulfate attack at low temperature
The changes in structural integrity and microstructure of Portland-limestone cement pastes were investigated in the course of magnesium sulfate attack at low temperature. A deterioration front, consisting of three distinct layers (brucite, gypsum, leached cement matrix), swelled in time due to the expansive nature of the deterioration products, generating cracks and subsequently detaching from the sound cement matrix, continuously promoting the process. Gypsum and thaumasite characterized the leached matrix, which experienced extensive cross-linking of the aluminosilicate structures, as a result of decalcification and dealumination of the calcium silicate hydrates (C(A)SH), impairing the overall mechanical performance. CSH of low packing density was most severely affected by the process, as confirmed by the significant drop in nano-mechanical properties. The increased rate of deterioration with limestone content was tentatively attributed to the prevalent morphology of the CSH phase. Results were validated by thermodynamic simulations, indicating that the real systems did not reach equilibrium.
36 MATERIALS SCIENCE↗
Advanced neutron absorber Ni-Cr-Mo-Gd alloys seawater corrosion mechanism and susceptibility study
Previous studies demonstrated the corrosion susceptibility of advanced neutron absorber (ANA) Ni-Cr-Mo-Gd in a seawater environment but remained inconclusive. In this paper, scanning electron microscopy was employed to identify the corrosion phase in Ni-Cr-Mo-Gd, and computational thermodynamic simulation was used to study phase corrosion potentials. Results showed that the Ni 5 Gd second phase, distributed along FCC grain boundaries in Ni-Cr-Mo-Gd, has lower corrosion potential than the substrate. Furthermore, heat treatment and alloy chemistry adjustment would not ameliorate the ANA corrosion susceptibility. Finally, isolating the Ni 5 Gd from the corrosion medium through advanced manufacturing is a viable way to improve the ANA corrosion resistance.
36 MATERIALS SCIENCE↗
Process-driven roadmap for depositing super duplex stainless steel via wire Arc additive manufacturing
Here, this study systematically investigates the effects of shielding gas, bead spacing, weld mode, and travel speed on the phase balance, porosity, and hardness of wire arc additively manufactured (WAAM) super duplex stainless steel (ER2594). Robotic WAAM was employed to fabricate multilayer walls under systematically varied process conditions, followed by phase transformation simulations, X-ray computed tomography (XCT), electron backscatter diffraction (EBSD), and microhardness evaluation. Thermodynamic simulations predicted rapid cooling of AM process can suppress the potential formation of deleterious precipitates which was later validated via cross-sectional microstructure analyses of printed samples. XCT revealed porosity levels below 0.2% for all deposits, with reduced travel speed significantly lowering defect volume. Microstructural analyses revealed the evolution of various austenite precipitates, including grain boundary austenite (GBA), Widmanstätten austenite (WA), and intergranular austenite (IGA), sequentially upon cooling of the ferrite phase. Among all process parameters, weld transfer mode exhibited the strongest influence on phase balance; pulsed mode promoted higher ferrite retention (~ 36%) compared to RapidX mode. No consistent relationship between stabilized phase fraction and captured microhardness was observed. This work provides critical insights for optimizing WAAM parameters to control phase balance and mechanical performance, which is essential for producing high-integrity super duplex stainless-steel components for nuclear and marine applications.
Grain orientation↗
A unifying equation for fermentation sustainability across the titer-rate-yield landscape
Industrial fermentation is central to the sustainable production of fuels and chemicals, yet commercial viability of emerging technologies hinges on improving fermentation titer, rate, and yield (TRY). How these metrics shape system cost remains difficult to generalize due to complex interactions among feedstocks, fermentation, separations, catalytic upgrading, waste management, and facility design. Here, we systematically map theoretical fermentation performance spaces (formed by all potential TRY combinations) for 32 representative biomanufacturing facilities—spanning distinct choices for feedstocks, fermentation regimes and products, separations, and catalytic upgrading—by simulating and evaluating them (via techno-economic analysis, TEA) under uncertainty (600,000 Monte Carlo simulations) and across TRY combinations (7500 TRY combinations for each of 32 configurations). Across this wide design and thermodynamic simulation space, we find the relationship between fermentation TRY and system cost is captured by a simple, generalizable mathematical equation (R 2 of 0.992 − 1.000 across our simulations; 0.954 − 1.000 when validated against prior studies that used different tools). We use this equation to elucidate key drivers that shape cost sensitivity to fermentation performance, generating widely applicable insights. By demonstrating a unifying relationship governs the impact of fermentation on biomanufacturing economics, this work establishes a foundation for agile, holistically predictive, resource-efficient strategies to prioritize fermentation research and development needs and accelerate commercialization of emerging biomanufacturing technologies.
applied mathematics↗
Changes in Four Decades of Near‐CONUS Tropical Cyclones in an Ensemble of 12 km Thermodynamic Global Warming Simulations
We evaluate tropical cyclones (TCs) in a set of thermodynamic global warming (TGW) simulations over the continental United States (CONUS). A 12 km simulation forced by ERA5 provides a 40‐year historical (1980–2019) control. Four complimentary future scenarios are generated using thermodynamic deltas applied to lateral boundary, interior, and surface forcing. We curate a data set of 4,498 6‐hourly TC snapshots in the control and find a corresponding “twin” in each counterfactual, permitting a paired comparison. Warming results in an increase in mean dynamical TC intensity and moisture‐related quantities, with the latter being more pronounced. TC inner cores contract slightly but outer storm size remains unchanged. The frequency with which TCs become more intense is only moderately consistent, with snapshots having increased hazards ranging from 50% to 80% depending on warming level. The fractions of TCs undergoing rapid intensification and weakening both increase across all warming simulations, suggesting elevated short‐term intensity variability.
54 ENVIRONMENTAL SCIENCES↗
LANL Contributions to pyiron: An integrated development environment for computational materials science
To support and accelerate the development of simulation protocols in atomistic modelling, we introduce an integrated development environment (IDE) for computational materials science called pyiron (http://pyiron.org). The pyiron IDE combines a web based source code editor, a job management system for build automation, and a hierarchical data management solution. The core components of the pyiron IDE are pyiron objects based on an abstract class, which links application structures such as atomistic structures, projects, jobs, simulation protocols and computing resources with persistent storage and an interactive user environment. The simulation protocols within the pyiron IDE are constructed using the Python programming language. To highlight key concepts of this tool as well as to demonstrate its ability to simplify the implementation and testing of simulation protocols we discuss two applications. In these examples we show how pyiron supports the whole life cycle of a typical simulation, seamlessly combines ab initio with empirical potential calculations, and how complex feedback loops can be implemented. While originally developed with focus on ab initio thermodynamics simulations, the concepts and implementation of pyiron are general thus allowing to employ it for a wide range of simulation topics.
Janssen, Jan↗
Flower‐Type Organized Trade‐Wind Cumulus: A Multi‐Day Lagrangian Large Eddy Simulation Intercomparison Study
Shallow cumulus cloud fields in subtropical marine trade wind environments, particularly over the tropical Atlantic Ocean, show distinct organizational patterns. Among these, Flower‐type clouds are characterized by expansive stratiform cloud patches surrounded by regions of scattered convection. The objectives of this study were (a) to construct a case study of a time period during the EUREC 4 A/ATOMIC field campaign when Flower‐type organization was observed, (b) to evaluate the fidelity of a multi‐model ensemble of large eddy simulations of that case, and (c) to analyze the interaction between cloud and precipitation processes and mesoscale organization in the simulations. The simulations follow a quasi‐Lagrangian trajectory, allowing mesoscale features to develop over time in a domain that follows the boundary‐layer airmass. The results show a broad agreement in simulated thermodynamic properties across different LES codes, with Flower‐type cloud patches appearing within hours of each other. The consensus among models is consistent with observations made during the EUREC 4 A/ATOMIC field campaign on the specific day of interest. The cloud structure reveals three distinct peaks in the joint probability densities of cloud base and cloud top height, with the dominant peak at any given time influenced by the stage of cloud organization. The simulated cloud system evolution reveals consistent occurrence of maxima in liquid water path and rain rate before Flower reaches its maximum length scale. Targeted sensitivity tests reveal a weak relationship between Cloud Droplet Number concentration and the extent/degree/type of organization.
EUREC4A↗
CLM5 Simulations of Soil Moisture and Gross Primary Productivity for CONUS at 0.125 degrees
This dataset provides 0.125-degree gridded simulations of soil moisture and gross primary productivity (GPP) for the Contiguous United States (CONUS), generated using the Community Land Model version 5 (CLM5) with the biogeochemistry module enabled. The data covers a historical baseline (1980-2015) and mid-century future projections (2020-2055). Future projections are organized into two sets of scenarios to distinguish the impacts of different drivers: (1) Atmospheric Only (ATM): These scenarios apply future atmospheric forcings while holding land use and land cover (LULC) at historical baseline levels. The atmospheric forcings represent moderately versus severely hotter/drier atmospheric conditions (dynamically downscaled perturbed thermodynamics simulations based on CMIP6 SSP245 and SSP585 warming signals), each with cooler versus hotter Earth System Model temperature sensitivity instantiations. These scenarios are identified in the folder names as rcp45_cooler_near, rcp45_hotter_near, rcp85_cooler_near, and rcp85_hotter_near. (2) Coupled Atmospheric and Land-Use (LAND+ATM): These scenarios apply future atmospheric forcing together with future LULC by pairing atmospheric pathways with lower versus higher population/economic growth scenarios representing Shared Socioeconomic Pathways 3 and 5 (SSP3 and SSP5). These scenarios are identified in the file names as ssp3_rcp45_cooler_near, ssp3_rcp45_hotter_near, ssp5_rcp85_cooler_near, and ssp5_rcp85_hotter_near. Please refer to the "README_first.md" file for detailed information on file structure, variables, units, and data formats.
drought↗
CLM5 Simulations of Soil Moisture and Grain Carbon for CONUS at 0.125 degrees
This dataset provides 0.125° gridded simulations of soil moisture and crop grain carbon for the Contiguous United States (CONUS), generated using the Community Land Model version 5 (CLM5) with the biogeochemistry module enabled. The data covers a historical baseline (1980–2015) and mid-century future projections (2020–2055). Future projections are organized into two sets of scenarios to distinguish the impacts of different drivers: (1) Atmospheric Only (ATM-only): These scenarios apply future atmospheric forcings while holding land use and land cover change (LULCC) at historical baseline levels. The atmospheric forcings represent moderately versus severely hotter/drier atmospheric conditions (dynamically downscaled perturbed thermodynamics simulations based on CMIP6 SSP245 and SSP585 warming signals), each with cooler versus hotter Earth System Model temperature sensitivity instantiations. These scenarios are identified in the file names as atm45cooler, atm45hotter, atm85cooler, and atm85hotter. (2) Coupled Atmospheric and Land-Use (LAND+ATM): These scenarios apply future atmospheric forcing together with future LULCC by pairing atmospheric pathways with lower versus higher population/economic growth scenarios representing Shared Socioeconomic Pathways 3 and 5 (SSP3 and SSP5). These scenarios are identified in the file names as atm45cooler_ssp3, atm45hotter_ssp3, atm45cooler_ssp5, atm45hotter_ssp5, atm85cooler_ssp3, atm85hotter_ssp3, atm85cooler_ssp5, and atm85hotter_ssp5. Please refer to the README file for detailed information on file structure, variables, units, and data formats.
Yao, Lili [Pacific Northwest National Laboratory] ↗
Microstructural refinement in ultrasonically modified A356 aluminum castings
Two A356 aluminum alloys (Al-Si-Mg), one with 0.09 wt.% Fe and one with 0.91 wt.% Fe, were cast in a graphite mold with the simultaneous application of local ultrasonic intensification to refine the as-cast microstructure. Ultrasonication during casting transformed the morphology of primary Al grains from dendritic (~140-290 microns in size) to globular (~33-36 microns in size). The alloy with high Fe exhibited globular grains at distances up to 45 mm away from the ultrasound probe, while the alloy with low Fe exhibited globular grains at distances only up to 6 mm away from the ultrasound probe. Near the location of the ultrasound probe (< 2 mm away), a second non-dendritic microstructural morphology was observed with fine aluminum grains (~9-25 microns in size). This unique fine-grained morphology has not been previously reported, contains a greater concentration of Si relative to the globular microstructure, and may be a large, fully eutectic region. Ultrasonication during casting also transformed the morphology of the ß-Al 5 FeSi phase particles (which are deleterious to the strength and ductility of the alloy) in the high Fe alloy from needle-like to rectangular, which could enable the greater use of secondary Al alloys. Thermodynamic simulations conducted to calculate the solidification paths of the two alloys studied predict that the ß-Al 5 FeSi phase begins to form earlier in the alloy with high Fe. Finally, data suggest that the ß-Al 5 FeSi phase (which is more abundant in alloys with high Fe content) may enhance ultrasonically-induced grain refinement.
36 MATERIALS SCIENCE↗
Strontium Effects on the Formation of Iron-Intermetallic Phases in Secondary Al–9Si–0.6Fe Alloys
The presence and morphology of Fe-containing intermetallic phases affect the mechanical properties of aluminum alloys, especially in secondary Al–Si-based cast alloys. Although strontium (Sr) addition of 50 to 500 ppm is known to refine the needle-type eutectic silicon structure, the influence of Sr on the formation of Fe-intermetallic phases remains unclear. The present work investigates the combined additions of Sr and Mn to Al–9Si–0.6Fe–0.35Mg (All compositions are in wt pct except otherwise stated.) alloys on the formation of Fe-intermetallic phases at different solidification rates from ~ 1.5 to ~ 60 °C/s. Long and branched-type AlFeSi phase with size ranging from 50 to 120 µm are more common when solidified at the rate of 1.5 °C/s regardless of Sr and Mn additions. However, at the fast solidification rate of 60 °C/s, a 60 ppm Sr addition significantly reduced the average length of needle-shaped AlFeSi phase to less than 3 to 5 µm. Thermodynamic simulations have been performed using CALculation of PHAse Diagrams (CALPHAD) models to predict the formation of various phases and their possible interactions during solidification. The results indicated that the combination of a high solidification rate and about 60 ppm of Sr is beneficial to refining the δ-Al 3 FeSi 2 phase in Al–Si–Mg alloys containing 0.6 pctFe. As a result, this unexpected finding of Fe-intermetallic refinement by low Sr addition (~60 ppm) provides an important guide in designing secondary alloys for sustainable casting applications.
36 MATERIALS SCIENCE↗
Functionalized benzylamines from commercial kraft lignin
Benzylamines are key intermediates in pharmaceuticals, agrochemicals, and polymers, but their conventional production relies on benzyl chloride - a petroleum-derived compound with high toxicity and energy demands. Lignin, accounting for up to 30% of plant biomass, is the largest renewable source of aromatic carbon on Earth. However, its highly complex and recalcitrant structure poses a major barrier to efficient conversion into high-value chemicals. Here, in this study, we developed a catalytic approach to convert commercial kraft lignin into phenolic benzylamines through selective depolymerization and subsequent functionalization. We systematically evaluated the effects of three alcohol solvents, formic acid (FA), and a ruthenium-on‑carbon (Ru/C) catalyst on monophenol yield and selectivity. Up to 6.5 wt% monophenol yield was achieved using methanol (MeOH), FA, and Ru/C at 300 °C for 2 h. Quantum thermodynamic simulations based on the COSMO-RS model confirmed the superior solvation and reactivity of the MeOH + FA system, rationalizing observed product yield. The purified monophenolic products, primarily guaiacol and alkyl guaiacols, were then converted into functionalized benzylamines with >90% yield via a multicomponent Mannich reaction under mild conditions. Techno economic analysis (TEA) and life cycle assessment (LCA) underscore the importance of improving lignin depolymerization yields and expanding biorefinery scale. Solvent-only configurations outperform other options in both cost and emissions, with the methanol-only case performing the best ($\$$105 /kg and 26 kg CO 2e /kg) at a large-scale facility. This study establishes a scalable, bio-based pathway for producing benzylamines from commercial kraft lignin, advancing lignin valorization and offering a sustainable alternative to produce petrochemical-based benzylamines.
Catalytic reduction↗
Effect of Cr and Ni concentrations on resilience of cast Nb- alloyed heat resistant austenitic steels at extreme high temperatures
Austenitic Cr–Ni alloyed heat resistant steels with Nb additions are used for intensively thermo-mechanically loaded cast components working in extreme high temperature oxidizing environment. Their performance during static oxidation and transient thermo-mechanical loading was investigated to recommend an optimal cost-effective Cr/Ni composition of Nb-alloyed austenitic class steels. Here, the static oxidation and transient thermo-mechanical behavior of three austenitic steels with different Cr/Ni alloying levels were investigated and compared for variety of working conditions. Static oxidation was performed between 900 °C and 1000 °C in air for 400 h. The critical temperature which increases spallation during static oxidation was determined for each of the steel alloying levels. In addition, thermal cycling of a constrained specimen was done with varying upper cycling temperatures between 850 °C and 1000 °C. SEM and TEM analyses were supported by thermodynamic simulation of the phases precipitated in the metal matrix and the structure of formed oxide layers. These studies were used to determine the mechanisms of degradation of thermo-mechanically loaded Cr/Ni austenitic steels at extreme high temperatures. A recommendation for a cost-effective Cr/Ni alloying level for different working conditions was determined.
36 MATERIALS SCIENCE↗
Sigma phase evolution and nucleation mechanisms revealed by atom probe tomography in a 347H stainless steel
The size evolution and phase composition of sigma phases were investigated for a 347H stainless steel subject to isothermal aging at 750 °C for up to 10,000 h. Scanning electron microscopy reveals that sigma phases are present before 336 h aging and they continue to grow for all aging times studied. Atom probe tomography shows little variation in the sigma phase composition with aging time up to 10,000 h, and only the C content decreases with aging time. The comparison of C concentration suggests that the sigma phase does not nucleate within the C-depleted matrix or precipitate free grain boundaries, leaving dissolving metastable M 23 C 6 as the only possible nucleation site. Based on the experimental results and thermodynamic simulations, the desirable Nb concentration is discussed to reduce the kinetics of sigma phase growth, and possible design directions are suggested to improve 347H.
36 MATERIALS SCIENCE↗
Sustainable bioleaching of lithium-ion batteries for critical metal recovery: Process optimization through design of experiments and thermodynamic modeling
Recycling spent lithium-ion batteries (LIBs) could alleviate supply risks for critical metals and be less harmful to the environment compared to new production of metals from mining. Developing a cost-effective LIB bioleaching process could be a promising alternative to traditional energy-intensive recycling technologies. Here, this study aimed to optimize bioleaching conditions for maximum economic competitiveness through design of experiments using iterative response surface methodology (RSM), assisted by thermodynamic modeling. The optimal condition was identified as 2.5% pulp density in 75 mM gluconic acid biolixiviant at 55°C for 30 h which could recover 57%–84% of nickel, 71%–86% of cobalt, and 100% of lithium and manganese, yielding a 17%–26% net profit margin. The recommended pulp density and acid concentrations, together with the observed metal solubilization, were supported by thermodynamic modeling predictions. Our study demonstrated that combining RSM with thermodynamic simulations could be a powerful tool for optimizing bioleaching conditions.
60 APPLIED LIFE SCIENCES↗