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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Analysis of phase stability and chemical segregation in the Mo-V alloys using a generalized embedded atom method potential

A new interatomic potential for the Mo-V system is introduced to facilitate the study of phase stability and mechanical properties at lower temperatures. This potential is based on a generalization of the embedded atom method and includes contributions from embedding energy, explicit two- and three-body interactions and nonlocal many-body interaction terms. The parameters of the potential are optimized by using data from ab initio density functional theory (DFT) calculations. The potential is rigorously validated across a range of physical properties, such as elastic constants, equation of states, phonon dispersion curves, point defect properties and melting temperatures for different compositions. Even though our potential is trained on a small dataset, its accuracy is comparable to available machine learning potentials for Mo and V. Furthermore, our results show that an ordered B2 phase is stable at low temperatures in alloys containing 50% V, but the solid solution phase is stable above 800 K. However, such long-range ordering is not observed in V-rich or Mo-rich alloys. In addition, our results show that V segregates to dislocation cores and grain boundaries.

36 MATERIALS SCIENCE↗

DOE OSTI2020

High-temperature Majorana fermions in magnet-superconductor hybrid systems

Magnet-superconductor hybrid (MSH) structures represent one of the most promising platforms to realize, control, and manipulate Majorana modes using scanning tunneling methods. By depositing either chains or islands of magnetic atoms on the surface of a conventional, elemental superconductor such as Pb or Re, topological superconducting phases can emerge. They feature either localized Majorana bound states at the chain ends or dispersing chiral Majorana modes at the island's boundary. However, some of these experiments have not reached the spectral resolution to clearly distinguish between topological Majorana and trivial Shiba states due to very small superconducting gap sizes and experiments performed at sub-Kelvin temperatures. Here we consider superconducting substrates with unconventional spin-singlet pairing, including high-temperature d -wave and extended s -wave superconductors. We derive topological phase diagrams and compute edge states for cylinder and island geometries and discuss their properties. Several time-reversal invariant topological superconducting phases of the Zhang-Kane-Mele type are found and discussed. Addiotnally, we review one-dimensional MSH structures and show that parameters to realize topologically nontrivial magnetic chains embedded into a larger, two-dimensional substrate differ from the purely one-dimensional case. Quite generally we find that unconventional superconducting substrates work as well as the conventional s -wave substrates to realize topological phases. In particular, iron-based pnictide and chalcogenide superconductors are the most promising class of substrates for future high-temperature MSH systems.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Cartesian Mesh Simulations for the Third AIAA Sonic Boom Prediction Workshop

Simulation results are presented for all cases from the Third AIAA Sonic Boom Prediction Workshop. An inviscid, embedded-boundary Cartesian-mesh flow solver is used in conjunction with adjoint-based mesh adaptation to compute nearfield pressure signatures. Specialized techniques are applied to maximize accuracy and minimize cost on Cartesian meshes. The Richardson-based error estimate highlights regions of the signatures most sensitive to mesh refinement. Timing results and coarse, medium, and fine mesh sizes for nearfield cases demonstrate that the parallel decomposition approach is efficient in both computational time and wall-clock. Pressure signals are propagated to the ground using an augmented Burgers’ equation solver to predict boom carpets. Ground signatures and loudness metrics are presented for a standard atmosphere as well as more realistic atmospheric profiles, which affect overall noise levels and can significantly widen the boom carpet. Mesh convergence studies show that high sampling frequencies, around 500 kHz, are required for propagation, and the sampling frequency increases at large off-track angles with longer acoustic ray paths and propagation times. The numerical methods yield accurate results for predicting low sonic boom signatures while being among the least computationally expensive of the workshop.

ARMD↗

NASA NTRS1994

Evolution of dynamo-generated magnetic fields in accretion disks around compact and young stars

Geometrically thin, optically thick, turbulent accretion disks are believed to surround many stars. Some of them are the compact components of close binaries, while the others are throught to be T Tauri stars. These accretion disks must be magnetized objects because the accreted matter, whether it comes from the companion star (binaries) or from a collapsing molecular cloud core (single young stars), carries an embedded magnetic field. In addition, most accretion disks are hot and turbulent, thus meeting the condition for the MHD turbulent dynamo to maintain and amplify any seed field magnetic field. In fact, for a disk's magnetic field to persist long enough in comparison with the disk viscous time it must be contemporaneously regenerated because the characteristic diffusion time of a magnetic field is typically much shorter than a disk's viscous time. This is true for most thin accretion disks. Consequently, studying magentic fields in thin disks is usually synonymous with studying magnetic dynamos, a fact that is not commonly recognized in the literature. Progress in studying the structure of many accretion disks was achieved mainly because most disks can be regarded as two-dimensional flows in which vertical and radial structures are largely decoupled. By analogy, in a thin disk, one may expect that vertical and radial structures of the magnetic field are decoupled because the magnetic field diffuses more rapidly to the vertical boundary of the disk than along the radius. Thus, an asymptotic method, called an adiabatic approximation, can be applied to accretion disk dynamo. We can represent the solution to the dynamo equation in the form B = Q(r)b(r,z), where Q(r) describes the field distribution along the radius, while the field distribution across the disk is included in the vector function b, which parametrically depends on r and is normalized by the condition max (b(z)) = 1. The field distribution across the disk is established rapidly, while the radial distribution Q(r) evolves on a considerably longer timescale. It is this evolution that is the subject of this paper.

Stepinski, Tomasz F.↗

NASA NTRS2004

Design and Evaluation of Modifications to the NASA Langley Flow Impedance Tube

The need to minimize fan noise radiation from commercial aircraft engine nacelles continues to provide an impetus for developing new acoustic liner concepts. If the full value of such concepts is to be attained, an understanding of grazing flow effects is crucial. Because of this need for improved understanding of grazing flow effects, the NASA Langley Research Center Liner Physics Group has invested a large effort over the past decade into the development of a 2-D finite element method that characterizes wave propagation through a lined duct. The original test section in the Langley Grazing IncidenceTube was used to acquire data needed for implementation of this finite element method. This test section employed a stepper motor-driven axial-traversing bar, embedded in the wall opposite the test liner, to position a flush-mounted microphone at pre-selected locations. Complex acoustic pressure data acquired with this traversing microphone were used to educe the acoustic impedance of test liners using this 2-D finite element method and a local optimization technique. Results acquired in this facility have been extensively reported, and were compared with corresponding results from various U.S. aeroacoustics laboratories in the late 1990 s. Impedance data comparisons acquired from this multi-laboratory study suggested that it would be valuable to incorporate more realistic 3-D aeroacoustic effects into the impedance eduction methodology. This paper provides a description of modifications that have been implemented to facilitate studies of 3-D effects. The two key features of the modified test section are (1) the replacement of the traversing bar and its flush-mounted microphone with an array of 95 fixed-location microphones that are flush-mounted in all four walls of the duct, and (2) the inclusion of a suction device to modify the boundary layer upstream of the lined portion of the duct. The initial results achieved with the modified test section are provided in this report, and a comparison of these results with those achieved using the original test section is used to demonstrate that the data acquisition and analysis with the new test section can be confidently used for impedance eduction.

Jones, Michael G.↗

DOE OSTI2024

Classifying photonic topology using the spectral localizer and numerical K -theory

Recently, the spectral localizer framework has emerged as an efficient approach for classifying topology in photonic systems featuring local nonlinearities and radiative environments. In nonlinear systems, this framework provides rigorous definitions for concepts such as topological solitons and topological dynamics, where a system’s occupation induces a local change in its topology due to nonlinearity. For systems embedded in radiative environments that do not possess a shared bulk spectral gap, this framework enables the identification of local topology and shows that local topological protection is preserved despite the lack of a common gap. However, as the spectral localizer framework is rooted in the mathematics of C*-algebras, and not vector bundles, understanding and using this framework requires developing intuition for a somewhat different set of underlying concepts than those that appear in traditional approaches for classifying material topology. In this tutorial, we introduce the spectral localizer framework from a ground-up perspective and provide physically motivated arguments for understanding its local topological markers and associated local measure of topological protection. In doing so, we provide numerous examples of the framework’s application to a variety of topological classes, including crystalline and higher-order topology. We then show how Maxwell’s equations can be reformulated to be compatible with the spectral localizer framework, including the possibility of radiative boundary conditions. To aid in this introduction, we also provide a physics-oriented introduction to multi-operator pseudospectral methods and numerical K-theory, two mathematical concepts that form the foundation for the spectral localizer framework. Finally, we provide some mathematically oriented comments on the C*-algebraic origins of this framework, including a discussion of real C*-algebras and graded C*-algebras that are necessary for incorporating physical symmetries. Looking forward, we hope that this tutorial will serve as an approachable starting point for learning the foundations of the spectral localizer framework.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2013

Diagnosing Aircraft Icing Potential from Satellite Cloud Retrievals

The threat for aircraft icing in clouds is a significant hazard that routinely impacts aviation operations. Accurate diagnoses and forecasts of aircraft icing conditions requires identifying the location and vertical distribution of clouds with super-cooled liquid water (SLW) droplets, as well as the characteristics of the droplet size distribution. Traditional forecasting methods rely on guidance from numerical models and conventional observations, neither of which currently resolve cloud properties adequately on the optimal scales needed for aviation. Satellite imagers provide measurements over large areas with high spatial resolution that can be interpreted to identify the locations and characteristics of clouds, including features associated with adverse weather and storms. This paper describes new techniques for interpreting cloud products derived from satellite data to infer the flight icing threat to aircraft. For unobscured low clouds, the icing threat is determined using empirical relationships developed from correlations between satellite imager retrievals of liquid water path and droplet size with icing conditions reported by pilots (PIREPS). For deep ice over water cloud systems, ice and liquid water content (IWC and LWC) profiles are derived by using the imager cloud properties to constrain climatological information on cloud vertical structure and water phase obtained apriori from radar and lidar observations, and from cloud model analyses. Retrievals of the SLW content embedded within overlapping clouds are mapped to the icing threat using guidance from an airfoil modeling study. Compared to PIREPS and ground-based icing remote sensing datasets, the satellite icing detection and intensity accuracies are approximately 90% and 70%, respectively, and found to be similar for both low level and deep ice over water cloud systems. The satellite-derived icing boundaries capture the reported altitudes over 90% of the time. Satellite analyses corresponding to the time and location of several recent aviation accidents and with icing PIREPS are also presented that reveal skill in identifying severe icing conditions. These results demonstrate the utility of satellite cloud retrievals for quantitatively diagnosing the potential for icing conditions on temporal and spatial scales that should be useful to the aviation community. Plans are being developed to deliver these new satellite products to the GOES-R Proving Ground in the near future so that they can be evaluated in operational applications.

Smith, William L., Jr.↗

NASA NTRS2017

Design of an Axisymmetric Afterbody Test Case for CFD Validation

As identified in the CFD Vision 2030 Study commissioned by NASA, validation of advanced RANS models and scale-resolving methods for computing turbulent flow fields must be supported by continuous improvements in fundamental, high-fidelity experiments designed specifically for CFD implementation. In accordance with this effort, the underpinnings of a new test platform referred to herein as the NASA Axisymmetric Afterbody are presented. The devised body-of-revolution is a modular platform consisting of a forebody section and afterbody section, allowing for a range of flow behaviors to be studied on interchangeable afterbody geometries. A body-of-revolution offers advantages in shape definition and fabrication, in avoiding direct contact with wind tunnel sidewalls, and in tail-sting integration to facilitate access to higher Reynolds number tunnels. The current work is focused on validation of smooth-body turbulent flow separation, for which a six-parameter body has been developed. A priori RANS computations are reported for a risk-reduction test configuration in order to demonstrate critical variation among turbulence model results for a given afterbody, ranging from barely-attached to mild separated flow. RANS studies of the effects of forebody nose (with/without) and wind tunnel boundary (slip/no-slip) on the selected afterbody are presented. Representative modeling issues that can be explored with this configuration are the effect of higher Reynolds number on separation behavior, flow physics of the progression from attached to increasingly-separated afterbody flows, and the effect of embedded longitudinal vortices on turbulence structure.

Disotell, Kevin J.↗

NASA NTRSDate not supplied

Progress on the Development of a Step Height Sensor for the BOLT Flight Vehicle

This presentation will summarize progress on the development of a step height sensor for the BOLT flight vehicle. Two methods have been proposed to measure the step size in this effort.The first method involves the application of miniaturized camera embedded in the flight vehicle that views the step through a rearward-facing port (shown in Fig. 1a inset). The second method involves the application of a linear fiber optic array bundle to measure the intensity of light reflected back from the aft body step (concept shown in Fig. 1b). Preliminary testing with the miniaturized camera has been performed in the lab and shows that displacements of ≤10 μm can be measured using this method. Final testing with both methods will be performed on the test stand shown in Fig. 1a. This test stand will include a fine adjustment vertical translation stage that will be used to adjust the step height in steps of 1-2 μm. A high-magnification imaging system will also be used to verify the step height. The miniaturized camera and linear fiber optic array bundle will be mounted in one of several port holes with varying degrees of inclination relative to the top surface in the opposing aft-section slab. BOLT flight vehicle details and information on the steps can be found in Ref. [1].

BOLT↗

DOE OSTI2024

Accurate assessment of land–atmosphere coupling in climate models requires high-frequency data output

Land–atmosphere (L–A) interactions are important for understanding convective processes, climate feedbacks, the development and perpetuation of droughts, heatwaves, pluvials, and other land-centered climate anomalies. Local L–A coupling (LoCo) metrics capture relevant L–A processes, highlighting the impact of soil and vegetation states on surface flux partitioning and the impact of surface fluxes on boundary layer (BL) growth and development and the entrainment of air above the BL. A primary goal of the Climate Process Team in the Coupling Land and Atmospheric Subgrid Parameterizations (CLASP) project is parameterizing and characterizing the impact of subgrid heterogeneity in global and regional Earth system models (ESMs) to improve the connection between land and atmospheric states and processes. A critical step in achieving that aim is the incorporation of L–A metrics, especially LoCo metrics, into climate model diagnostic process streams. However, because land–atmosphere interactions span timescales of minutes (e.g., turbulent fluxes), hours (e.g., BL growth and decay), days (e.g., soil moisture memory), and seasons (e.g., variability in behavioral regimes between soil moisture and latent heat flux), with multiple processes of interest happening in different geographic regions at different times of year, there is not a single metric that captures all the modes, means, and methods of interaction between the land and the atmosphere. And while monthly means of most of the LoCo-relevant variables are routinely saved from ESM simulations, data storage constraints typically preclude routine archival of the hourly data that would enable the calculation of all LoCo metrics. Here, we outline a reasonable data request that would allow for adequate characterization of sub-daily coupling processes between the land and the atmosphere, preserving enough sub-daily output to describe, analyze, and better understand L–A coupling in modern climate models. A secondary request involves embedding calculations within the models to determine mean properties in and above the BL to further improve characterization of model behavior. Higher-frequency model output will (i) allow for more direct comparison with observational field campaigns on process-relevant timescales, (ii) enable demonstration of inter-model spread in L–A coupling processes, and (iii) aid in targeted identification of sources of deficiencies and opportunities for improvement of the models.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS2024

Accurate Assessment of Land-Atmosphere Coupling in Climate Models Requires High Frequency Data Output

Land-atmosphere (L-A) interactions are important for understanding convective processes, climate feedbacks, the development and perpetuation of droughts, heatwaves, pluvials, and other land-centred climate anomalies. Local L-A coupling (LoCo) metrics capture relevant L-A processes, highlighting the impact of soil and vegetation states on surface flux partitioning, and the impact of surface fluxes on boundary layer (BL) growth, development, and entrainment of air above the BL. A primary goal of the Climate Process Team on Coupling Land and Atmospheric Subgrid Parameterizations (CLASP) is parameterizing and characterizing the impact of subgrid heterogeneity in global and regional earth system models (ESMs) to improve the connection between land and atmospheric states and processes. A critical step in achieving that aim is the incorporation of L-A metrics, especially LoCo metrics, into climate model diagnostic process streams. However, because land-atmosphere interactions span time scales of minutes (e.g., turbulent fluxes), hours (e.g., BL growth and decay), days (e.g., soil moisture memory), and seasons (e.g., variability of behavioural regimes between soil moisture and latent heat flux), with multiple processes of interest happening in different geographic regions at different times of year, there is not a single metric that captures all the modes, means, and methods of interaction between the land and the atmosphere. And while monthly means of most of the LoCo-relevant variables are routinely saved from ESM simulations, data storage constraints typically preclude routine archival of the hourly data that would enable the calculation of all LoCo metrics. Here we outline a reasonable data request that would allow for adequate characterization of sub-daily coupling processes between the land and the atmosphere, preserving enough sub-daily output to describe, analyse, and better understand L-A coupling in modern climate models. A secondary request involves embedding calculations within the models to determine mean properties in and above the BL to further improve characterization of model behaviour. Higher-frequency model output will (i) allow for more direct comparison with observational field campaigns on process-relevant time scales, (ii) enable demonstration of inter-model spread in L-A coupling processes, and (iii) aid in targeted identification of sources of deficiencies and opportunities for improvement of the models.

Kirsten L. Findell↗

NASA NTRS2018

Aerodynamic Design and Optimization of Fan Stage for Boundary Layer Ingestion Propulsion System

The present paper addresses the process of preliminary design of a low-pressure fan and outlet guide vane (OGV) of a boundary layer ingestion (BLI) propulsion system. The tail-cone thruster systems of NASA's STARC_ABL (Single-aisle Turboelectric Aircraft with an Aft Boundary-Layer propulsor) adopts an axi-symmetric BLI type inlet as opposed to other embedded engine systems. Thus, the focus of the present work is placed on maximizing the efficiency of the fan and OGV stages under a significant radial distortion. A parameterization with B-spline function for camber line angles, metal chord, thickness distribution and stacking axis of blades is presented. The flowpath lines are also parameterized by B-spline function and aggregated in the design system of blades. The design optimization with evolutionary algorithm is performed with constraints of fan pressure ratio, OGV exit swirl angle and nozzle exit properties. The inlet conditions for the turbo-machinery CFD (Computational Fluid Dynamics) domain and the design goal of the fan stage are driven by a propulsion airframe integration (PAI) model that uses a 3-D unstructured RANS (Reynolds Average Navier Stokes) solver and actuator disk model. The expected power saving of the BLI propulsor is quantified via PAI analysis and the resulting preliminary design of the fan stages is compared with a clean-inlet flow propulsor.

Turbo-machinery↗

NASA NTRS2017

3-D-Observation of Matrix of MIL 090657 Meteorite by Absorption-Phase Tomography

MIL 090657 meteorite (CR2.7) is one of the least altered primitive carbonaceous c hondrites [1]. This meteorite has amorphous silicates like GEMS (glass with embedded metal and sulfide), which are characteristically contained in cometary dust, in matrix [2,3] as with the Paris meteorite [4]. Three lithologies have been recognized; lithology-1 (L 1) dominated by submicron anhydrous silicates, lithology-2 (L2) by GEMS-like amorphous silicates and lithology-3 (L3) by phyllosilicates [2]. Organic materials are abundant in L 1 and L2 [2,3]. L 1 and L2 were further divided into sub-lithology respectively based on their textures and compositions [5]. These studies were performed by 2D SEM and TEM observations of sample surfaces and thin sections that are unable to reveal what constitute each lithology and how these lithologies are distributed and related to each other. This information will provide important insights into alteration and aggregation processes on asteroids and in the early solar nebula. In this study, MIL 090657 matrix was examined in 3D using two types of X-ray tomography; DET (dual-energy tomography) [6] and SIXM (scanning-imaging X-ray microscopy) [7]. Mineral phases can be discriminated based on absorption contrasts at two different X-ray energies in DET. In SIXM, materials composed of light elements such as water or organic materials can be identified based on phase and absorption contrasts. By combining these methods, we can discriminate not only organic materials from voids but also hydrous alteration products, such as hydrated silicates and carbonates, from anhydrous minerals [8]. In this study, we first observed cross sections of MIL 090657 matrix fragments C1 00 mm) in detail using FE-SEM/ EDS. Based on the results, three house-shaped samples (3 0 -50 mm) were extracted from L 1, L2 and their boundary (H1, H3 and H5, respectively) using FIB. 3D imaging of these samples were conducted at BL47XU of SPring-8, a synchrotron radiation facility, with -30-40 nm/ voxel and - 70-80 nm/ voxel at 7keV and 8keV in DET and -100 nm/ voxel at 8keV in SIXM. We found new lithologies that we named L4, L5 and L6 in H1 and H3 in addition to L 1 and L2. L4. L5 and L6 are mainly composed of probably phyllosilicates with different Fe contents. Sulfide and framboidal magnetite were recognized in L4. L5 includes magnetite and carbonate and L6 includes anhydrous silicates having cracks inside. L 1, L2, L4 and L5 are porous while few voids were observed in L6. L4 adjoins to L 1 with boundary, which is not very distinct. L2, L5 and L6 adjoin to each other, and the boundaries of L6 with L2 and L5 are clear. In H5, coarse mineral grains C5-1 0 mm) such as Fe-metal and enstatite are present in L 1 and L2. L 1-L2 boundary is not sharp in 3 D. In conclusion, we found a variety of lithologies by 3D observation for the first time, suggesting that t he MIL 0 90657 meteorite experienced complex alteration and aggregation histories. As L2 is dominated by amorphous silicates, which are extremely susceptible to aqueous alteration, t his is p resumed to be t he most primitive lithology. The contact between L2 and phyllosilicate-bearing lithologies (L5 and L6) with clear boundaries indicates that they were aggregated after aqueous alteration of L5 and L6. The indistinct boundary between L 1 and L2 is suggesting that these two lithologies might originally be the same aggregate composed of amorphous silicates and coarse mineral grains. L 1 might have experienced weak aqueous alteration followed by mild thermal alteration [2], while L2 did not undergo aqueous alteration.

Miyama, Sugimoto↗

DOE OSTI2024

Baselining the Indirect Effect by Improving Quantification of Sea Spray and Marine Sources at Ascension Island (Final Report)

Oceans cover two-thirds of the Earth and understanding the interactions of aerosols with clouds in these large marine regions requires quantifying the man-made contributions to the budget of cloud-drop forming particles (known as cloud condensation nuclei, or CCN) relative to the non-manmade “baseline” conditions and understanding the meteorology of boundary layer clouds. Modeling studies have shown substantial uncertainties and sensitivities to natural marine CCN sources, meaning that to reduce uncertainties in indirect effects we must be able to better quantify the CCN budget in ocean regions. While models provide important constraints on these uncertainties, actually reducing uncertainties requires substantial observations in open-ocean and coastal regions in order to establish the baseline on which manmade emissions are added. The tropical South Atlantic Ocean is one of the least-sampled regions of the planet, making the comprehensive measurements of the Department of Energy Atmospheric Radiation Measurement Layered Atlantic Smoke Interactions with Clouds (LASIC) campaign provides the longest record of aerosol size distribution measurements from a differential mobility analyzer in a cloud-influenced marine location in the ARM database, with 17 months of ground-based aerosol size distribution measurements. This project addressed the research topic of Aerosol-Cloud Interactions (ACI) by supporting three publications from the LASIC measurements: 1. The ARM measurements were combined with a new value-added technique that was pioneered by the Russell group for quantifying sea salt. This quantification of sea salt uses supermicron scattering measurements for retrieving reasonable sea spray mass concentrations, providing the best-available, observationally-constrained estimate of the sea spray mode properties when supermicron size distribution measurements are not available. 2. The fitted modes of the distribution were used to investigate the signatures of cloud processing for very clean to very smoky aerosol conditions, revealing not only differences in the particles that activate in clouds but also in the mechanisms that control that droplet formation process. In clean air, the size required to form a cloud droplet is influenced by the number of particles, as well as how quickly particles take up water during growth in cloud. 3. Building on this aerosol characterization, cloud and meteorological conditions were used to evaluate aerosol-related changes in cloud albedo and optical depth. We introduced a new method of decomposing the impact of aerosols on clouds known as the Twomey effect by incorporating retrieved supersaturation from two independent sets of observations to constrain the feedback of aerosol particles on cloud properties. The method quantifies the reduction of the Twomey effect at high aerosol concentrations, which has never been explained quantitatively by observations. In addition, the results provide the first direct validation for the conditions observed in the tropical South Atlantic of a parcel-based approach that is embedded in many climate models. Together these findings illustrate how ARM extended field campaigns in stratocumulus-covered regions can be used to constrain ACI processes with direct observations, providing specific radiative effects without models. By making such process-specific constraints available to improve ACI in global climate models, ARM observations play a key role in supporting model development.

58 GEOSCIENCES↗

DOE OSTI2025

Convergent Manufacturing of Large-Scale Components for Nuclear Applications, via Additive Manufacturing and Powder Metallurgy Hot Isostatic Pressing

Powder metallurgy (PM)–hot isostatic pressing (PM-HIP) has long been recognized as a powerful route for producing fully dense, near net shape metallic components. By consolidating powders under high temperature and pressure, HIP provides isotropic properties, uniform microstructures, and scalability to complex geometries that are vital for sectors such as aerospace, energy, and nuclear power. Yet despite these advantages, the technology has remained constrained by costly trial and error canister fabrication, limitations of conventional forging, and incomplete knowledge about how the canister design influences final part properties. Additive manufacturing (AM), by contrast, thrives on design freedom and geometric flexibility but struggles with speed, scalability, and cost when applied to very large structures. The research presented in this report investigated how a convergent manufacturing approach, combining AM with PM-HIP, can merge the strengths of both technologies, leveraging AM’s flexibility for canister design and HIP’s consolidation capability to deliver reliable, large, and complex parts. The work progressed through three case studies that built on one another in scale and complexity. Small cylindrical canisters fabricated by conventional methods, laser powder bed fusion, and directed energy deposition were filled with stainless steel powders and subjected to HIP. The resulting parts demonstrated near-full density and mechanical properties on par with wrought stainless steel, showing for the first time that AM canisters can be a direct substitute for conventional ones without sacrificing quality. The next step involved a medium-scale, noncentrosymmetric T-valve, which is an enclosed, multibranch geometry that tested the limits of AM + PM-HIP integration. The T-valve achieved predictable shrinkage and uniform densification, confirming feasibility for enclosed designs. However, this study also revealed oxide inclusions and interfacial challenges at the AM + HIP boundary, underscoring the critical importance of controlling interface chemistry and employing robust, in situ strategies, such as melt pool monitoring and thermal monitoring, coupled with nondestructive evaluation techniques such as x-ray computed tomography. Finally, the effort culminated in fabricating a large-scale impeller weighing nearly 2000 lb and spanning 5 ft in diameter. Produced via multirobot wire arc AM and hot isostatic pressed to near-full density, the impeller validated industrial-scale feasibility. Predictive models closely matched experimental shrinkage, tensile properties were spatially uniform across the component, and the AM + PM-HIP interface proved mechanically sound despite the presence of oxide-decorated prior particle boundaries. This large-scale demonstration is a major milestone, showing that hybrid AM + PM‑HIP can reliably deliver components at reactor-relevant scales. Collectively, these studies charted a logical pathway: small-scale work built scientific confidence, medium-scale work highlighted opportunities and challenges, and large-scale work proved industrial impact. The overarching conclusion of this report is that AM + PM-HIP should not be seen as a replacement for forging but as a complementary pathway that provides the US with flexibility, resilience, and new options for manufacturing nuclear-grade components. Looking ahead, several directions emerge as critical to sustaining progress. Predictive modeling must become faster, more accessible, and more accurate, with digital twins and machine learning reducing reliance on trial and error. Powders and alloys must be optimized for HIP, with improved cleanliness, reduced oxides, and tailored chemistries that enhance creep, fatigue, and irradiation resistance. Interfaces between AM and HIP regions must be better engineered through coatings, machining strategies, and surface treatments to mitigate oxide formation and ensure reliable bonding to explore opportunities for HIP of targeted compositional parts, as well as multimaterial HIP cladding applications. Monitoring and nondestructive evaluation need to expand, incorporating multimodal sensors, x-ray computed tomography, and real-time data integration through platforms such as Pelican. At the same time, the pathway to industrial adoption requires techno-economic analysis, machinability studies, and qualification frameworks aligned with industry and regulatory standards. Finally, workforce and academic engagement must be strengthened. Programs that train technicians and engineers for US Navy and US Department of Energy manufacturing challenges should be paired with academic partnerships to support fundamental research, with open sharing of non-export-controlled data to accelerate innovation and build the next generation of experts. In conclusion, this report demonstrates that hybrid AM + PM-HIP is scientifically viable and strategically important. By combining the design agility of AM with the consolidation strength of HIP and embedding modeling, monitoring, and workforce development, this approach provided a transformative new capability for US manufacturing. The path forward is clear: hybrid AM + PM-HIP is not just a promising research direction but is also potentially an industrially relevant pathway that can reshape how nuclear-grade components are designed, qualified, and deployed.

36 MATERIALS SCIENCE↗