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

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Quantifying adherence of oxide scales on steels exposed to high temperature and pressure steam

Oxide scale exfoliation is a major concern in fossil fuel power generation because it can cause tube blockages and erode valves and steam turbine components downstream. There is still considerable scientific and commercial interest to improve the mechanistic understanding of oxide failures by developing models to predict exfoliation and the extent of tube blockage as a function of operating conditions and component geometries. Tensile testing inside a scanning electron microscope was conducted on ferritic–martensitic and austenitic steel specimens with the steam side (Fe,Cr)-rich oxides grown after exposures for up to 1000 h in steam with ~100 ppb O 2 at 276 bar and 550°C. Multiple oxide layer cracks and delamination events were observed and analyzed in detail during the tests. Results from the testing agreed well with earlier observations that had identified the failure location at the outer–inner oxide layer for all tested materials. Calculated adhesion energies identified the outer–inner oxide interface of alloy 347HFG as the weakest interface.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Corrosion evaluation of Ti–6Al–4V manufactured by electron beam melting in Ringer’s physiological solution: an in vitro study of the passive film

We report that electrochemical characteristics and semiconducting behavior of additively manufactured electron beam melted (EBM) and wrought (WR) Ti–6Al–4V (Ti-G5) are compared in Ringer’s physiological solution. X-ray diffraction (XRD) and field emission scanning electron microscopy (FE-SEM) confirmed the α+β structure of the tested materials, with two different microstructure types of “bimodal” and “basket-weave” for WR and EBM, respectively. Potentiodynamic polarization (PDP) revealed that the corrosion current density for EBM (i corr =0.27±0.06 μA cm -2 ) is less than the WR (i corr =0.70±0.05 μA cm -2 ). Moreover, potentiostatic polarization (PS) that was employed to form the passive layers at three different potentials of 300, 500, and 700 mV Ag/AgCl , showed that the passive films on the EBM sample are thinner. This finding was confirmed by electrochemical impedance spectroscopy (EIS). Furthermore, through Mott–Schottky (M–S) analysis, donor densities on WR passive films were found to be ~1.5 times larger than EBM. Although PS and EIS confirmed that the passive layer on EBM is thinner, it provides higher corrosion resistance than WR. The passive layer on both samples were found to have n-type characteristics with a duplex structure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

GPU acceleration of all-electron electronic structure theory using localized numeric atom-centered basis functions

We present an implementation of all-electron density-functional theory for massively parallel GPU-based platforms, using localized atom-centered basis functions and real-space integration grids. Special attention is paid to domain decomposition of the problem on non-uniform grids, which enables compute- and memory-parallel execution across thousands of nodes for real-space operations, e.g. the update of the electron density, the integration of the real-space Hamiltonian matrix, and calculation of Pulay forces. To assess the performance of our GPU implementation, we performed benchmarks on three different architectures using a 103-material test set. We find that operations which rely on dense serial linear algebra show dramatic speedups from GPU acceleration: in particular, SCF iterations including force and stress calculations exhibit speedups ranging from 4.5 to 6.6. For the architectures and problem types investigated here, this translates to an expected overall speedup between 3–4 for the entire calculation (including non-GPU accelerated parts), for problems featuring several tens to hundreds of atoms. Additional calculations for a 375-atom Bi2Se3 bilayer show that the present GPU strategy scales for large-scale distributed-parallel simulations.

42 ENGINEERING↗
DOE OSTI2021

Achieving Highly Reproducible Results in Graphite-based Li-ion Full Coin Cells

Electrode materials, cathodes or anodes, are mostly evaluated in half coin cells where lithium (Li) metal is used. However, due to the instability nature of Li metal, the cycling performances of the half cells is more likely reflecting Li anode stability instead of the coupled electrodes, questioning the conclusions. Full coin cells utilizing graphite as the anode effectively assesses materials. But the key factors of preparing full coin cells with reproducible performances have rarely been discussed and overlooked leading to many inconsistent results. This work discusses the scientific gap between cell preparation and observed electrochemical performances to unveil the key parameters for achieving consistent and reliable results in full coin cells, critical for effective evaluation of any new materials tested under relevant conditions. The knowledge from this work is broadly applicable in other full cells systems such as Si-based full cells or Na-ion batteries.

Hu, Jiangtao↗
DOE OSTI2021

In situ monitoring of dislocation, twinning, and detwinning modes in an extruded magnesium alloy under cyclic loading conditions

This work investigates the microscopic deformation mechanisms of an extruded, precipitation-strengthened AZ80 magnesium (Mg) alloy subjected to strain-controlled low-cycle fatigue using in situ neutron diffraction measurements. Results demonstrate that the plastic deformation during cyclic loading is dominated by the alternating {10.2} extension twinning and detwinning mechanisms. The observed deformation mode is strongly texture and precipitate dependent. For the initial texture, the tested material has two major texture components which result in the occurrence of extension twinning during both compression and reverse tension in the first two cycles. The prolonged detwinning process in the following cycles is proposed to relieve the shear stress field of {00.2} grains, leading to the disappearance of twinning. The precipitation strengthening results in an increase of the critical resolved shear stress (CRSS) by similar to 33 MPa for the extension twinning in this AZ80 alloy. Here, the synergistic effects of the initial texture, precipitation strengthening, and load sharing of various grain families and phases contribute to the complicated evolution of dominant deformation mechanisms, among which elevated dislocation activities are believed to be responsible for the relatively poor low-cycle-fatigue lifetime when compared to other Mg alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Crystal growth, scintillation properties & fast neutron-gamma discrimination of cubic halide perovskite CsCaCl 3 :(Eu 2+ , Tl + )

The vast variety of nuclear security applications require radiation detection materials tailored to their operational needs. A scintillator’s properties are strongly influenced by the choice of luminescent dopant, which facilitates customization to different applications. In this work, transparent Ø12 mm single crystals of undoped CsCaCl 3 , CsCaCl 3 :1% Eu, CsCaCl 3 :1% Tl, and CsCaCl 3 :1% Eu, 1% Tl were grown via the Vertical Bridgman method. Their scintillation properties and fast neutron-gamma discrimination capabilities were investigated. Undoped CsCaCl 3 had a light yield of 2,500 ph/MeV, which is the highest reported to date for this CVL material. The incorporation of Eu 2+ or Tl + into CsCaCl 3 as luminescence centers resulted in significantly higher light yields of ∼16,000 ph/MeV and energy resolutions of ∼8% at 662 keV. Compared to the single dopant counterparts, CsCaCl 3 :Eu, Tl had significantly suppressed afterglow; however, this came at the cost of reduced light yield. Among the materials tested, only CsCaCl 3 :Tl showed effective fast neutron and gamma discrimination capabilities, achieving a Figure of Merit of 3.2 between gamma-rays and fast neutron captures that produce protons and 1.6 between gamma-rays and fast neutron captures that produce alpha particles.

crystal growth↗
DOE OSTI2021

Role of deformation twinning in fatigue of CrCoNi medium-entropy alloy at room temperature

Here cylindrical specimens of CrCoNi alloy with electropolished surfaces were subjected to constant total strain amplitude low cycle fatigue. The alloy exhibited an initial period of cyclic hardening followed by cyclic softening until failure occurred. At the end of hardening stage at the peak of cyclic stress, well-developed persistent slip markings (PSMs) consisting of extrusions and intrusions were associated with thin deformation twins. A sophisticated experimental workflow was designed to extract information from the surface and the bulk of tested material. A combination of SEM, EBSD, ECCI, FIB and HR-STEM was used to study the internal structure and the surface profiles around the deformation twins, which were produced during the initial period of cyclic loading. Furthermore, localized cyclic plastic strain and stress concentrations near deformation twins led not only to early, well-developed PSMs, but also to the activation of TWIP and TRIP plasticity even at low macroscopic stress amplitudes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Capture of volatile RuO 4 from oxidized simulated used nuclear fuel solutions

Ruthenium is a challenging fission product in used nuclear fuel (UNF) reprocessing due to its complex redox chemistry, variable speciation in nitric acid, partial extractability, and volatility. This work presents a strategy for Ru removal based on the volatilization of RuO 4 using the strong oxidant sodium bismuthate, followed by RuO 2 deposition onto various substrates. Among the materials tested, polymer-based substrates such as polyolefin wax film (Parafilm®), exhibited superior performance, achieving up to near-quantitative Ru removal from solution. After dissolution of the substrate, 99.6% of the Ru was recovered as RuO 2 . The deposition mechanism onto the polyolefin wax film involves both physisorption and chemical reaction through oxidative cleavage of olefinic bonds within the polymer. In contrast, on inorganic substrates such as Al foil, RuO 4 undergoes incomplete surface adsorption and reduction, as confirmed by FTIR and XPS analyses. This approach remains effective under conditions of simulated oxidation of UNF solutions, selectively removing Ru while leaving other fission products in solution. As a result, capture of RuO 4 offers a practical and efficient strategy for ruthenium decontamination and recovery, offering a route for integration into existing UNF reprocessing flowsheets to enhance overall process safety and performance.

Ruthenium↗
DOE OSTI2024

Flux and estimated spectra from a low-intensity laser-driven X-ray source

Laser-driven X-rays as probes for high-energy-density physics spans an extremely large parameter space with laser intensities varying by 8 orders of magnitude. We have built and characterized a soft X-ray source driven by a modest intensity laser of 4 × 10 13 W/cm 2 . Emitted X-rays were measured by diamond radiation detectors and a filtered soft X-ray camera. A material-dependence study on Al, Ti, stainless steel alloy 304, Fe, Cu and Sn targets indicated 5-μm-thick Cu foils produced the highest X-ray yield. X-ray emission in the laser direction and emission in the reverse direction depend strongly on the foil material and the thickness due to the opacity and hydrodynamic disassembly time. The time-varying X-ray signals are used to measure the material thinning rate and is found to be ~1.5 μm/ns for the materials tested implying thermal temperature around 0.6 eV. The X-ray spectra from Cu targets peaks at ~2 keV with no emission >4 keV and was estimated using images with eight different foil filters. One-dimensional hydrodynamic and spectral calculations using HELIOS-CR provide qualitative agreement with experimental results. Modest intensity lasers can be an excellent source for nanosecond bursts of soft X-rays.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

Algae Asphalt to Enhance Pavement Sustainability and Performance at Subzero Temperatures

This paper evaluates the potential of algae-derived biobinders as sustainable alternatives for pavement construction. It specifically examines the physicochemical and rheological properties of biomodified binders and their potential to offset carbon emissions when used as partial replacements for conventional petroleum-based asphalt binders. Biosequestration of CO 2 using microalgal cell factories is a promising way of recycling CO 2 into biomass via photosynthesis. Our study demonstrates that incorporating algae-derived binders into asphalt can significantly reduce carbon emissions. Each 1% increase in algae-based biobinder leads to an approximate 4.5% decrease in net carbon emissions. This indicates that a blend containing about 22% biobinder has the potential to achieve carbon neutrality. Blends with higher proportions may even result in net-negative emissions, highlighting a promising strategy for environmentally responsible road construction. In terms of performance, the study shows that certain algae-derived biobinders significantly enhance the cracking resistance of asphalt, particularly under subzero temperatures, by improving its stress-relief capacity. A key contribution of this work is the introduction of polarizability as a novel molecular-level parameter for assessing the compatibility of algae-derived bio-oils with asphalt. By capturing the electronic responsiveness of bio-oil molecules, polarizability serves as a predictive indicator of their interaction potential with asphalt components, providing a new dimension for evaluating the binder performance at the molecular scale. Among the tested materials, the biobinder derived from Haematococcus pluvialis demonstrated particularly strong improvements in resistance to permanent deformation under repeated loading conditions analogous to traffic-induced stress, as well as enhanced resistance to moisture-induced damage. In conclusion, these findings advance the chemistry-driven design of biomass-based binders and highlight a promising pathway toward the development of low-carbon, high-performance, and sustainable infrastructure materials.

Algae↗
DOE OSTI2025

Generating multi-scale Li-ion battery cathode particles with radial grain architectures using stereological generative adversarial networks

Abstract Understanding structure-property relationships of Li-ion battery cathodes is crucial for optimizing rate-performance and cycle-life resilience. However, correlating the morphology of cathode particles, such as in LiNi0.8Mn0.1Co0.1O2 (NMC811), and their inner grain architecture with electrode performance is challenging, particularly, due to the significant length-scale difference between grain and particle sizes. Experimentally, it is not feasible to image such a high number of particles with full granular detail. A second challenge is that sufficiently high-resolution 3D imaging techniques remain expensive and are sparsely available at research institutions. Here, we present a stereological generative adversarial network-based model fitting approach to tackle this, that generates representative 3D information from 2D data, enabling characterization of materials in 3D using cost-effective 2D data. Once calibrated, this multi-scale model can rapidly generate virtual cathode particles that are statistically similar to experimental data, and thus is suitable for virtual characterization and materials testing through numerical simulations. A large dataset of simulated particles with inner grain architecture has been made publicly available.

25 ENERGY STORAGE↗
DOE OSTI2020

Cryogenic goniometer for measurements in pulsed magnetic fields fabricated via additive manufacturing technique

Complex high-precision mechanical devices can be fabricated using 3-dimensional printing technology with the help of computer-aided design. Using 3D stereolithography, we have constructed a cryogenic goniometer for measurements in pulsed magnetic fields of up to 100 T, at temperatures as low as 0.5 K. We review the properties of several materials tested in developing the goniometer and report on its design and performance. The goniometer allows samples to be rotated in situ to a precision of 0.2 deg, so that the field can be applied at many different angles to the samples’ symmetry directions. Following its success, we establish that 3D printing is now a viable technology for pulsed-field and other cryogenic probes.

3D printing↗
DOE OSTI2023

Numerical Simulations of Flow-Induced Deflections in MITR LEU Fuel Plate Due to Channel Size Disparity

The hydromechanical stability of the fuel plates in parallel coolant channels of a Materials Testing Reactor (MTR) fuel element design is of great importance to the safety of research and test reactors. Previous analytical, experimental, and numerical efforts focused on parallel channels with the same or similar size; also, in the prior numerical simulations, the fuel plate was often assumed to be perfectly flat. This work presents the results of a fluid-structure interaction simulation performed to evaluate the flow-induced deflections of the fuel plates in the low-enriched uranium (LEU, <20 wt% 235 U) fuel element design for the conversion (from highly enriched uranium) of the Massachusetts Institute of Technology Reactor (MITR-II, also referred to as MITR). Various manufacturing and assembly tolerances of the MITR LEU elements are considered in the analysis, and the effects of channel size disparity, nonideal plate shape, and flow rate uncertainty are investigated. Results show that, for all cases analyzed, the deflection occurs toward the larger channel, and the change in any channel stripe remains small (less than 0.021 mm) compared to fabrication tolerances. In addition to simulation work, a hydraulic performance test of the MITR LEU fuel element is currently planned to support conversion to the use of LEU fuel.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Additive Manufacturing of Cryogenic Austenitic Steel JK2LB via Wire-Fed Directed Energy Deposition (DED) for Fusion Energy Applications

This study explores the feasibility of fabricating cryogenic austenitic steel JK2LB via both laser-based directed energy deposition (laser-DED) and arc-based directed energy deposition (arc-DED) additive manufacturing processes for potential application in fusion reactors. JK2LB, a low-nickel, high-manganese stainless steel developed for ITER, offers excellent cryogenic toughness, radiation resistance, and decay-to-clearance characteristics. Although JK2LB was originally designed to endure cyclic stresses at cryogenic temperatures in tokamaks, its low-temperature mechanical integrity and radiation tolerance also make it a promising candidate for structural components, such as the coil case/support structure in nonplanar high-temperature superconducting magnet assemblies in stellarators. Directed energy deposition (DED) additive manufacturing was selected for this study due to its capability to fabricate large structures with complex geometries. Here, to address the long lead time and high cost associated with acquiring conventional JK2LB solid wire, JK2LB powder-cored wire was developed as the feedstock material. Testing blocks were then fabricated using both wire-fed laser-DED and arc-DED processes. Microstructural and compositional analyses revealed that both DED approaches yield fully austenitic phase and columnar grain structures. Mechanical testing at room temperature revealed that both DED routes achieved yield strength and elongation comparable to those of conventionally processed JK2LB via vacuum melting, electroslag remelting, extrusion, and drawing, though ultimate tensile strength was reduced due to Mn loss and large columnar grains. As a study mainly focusing on the additive manufacturing process, this work demonstrates the potential of additive manufacturing for fusion energy applications and provides a basis for optimization and future cryogenic mechanical evaluation.

Cryogenic steel↗
DOE OSTI2025

Measurements of attenuation and scattering properties of water-based liquid scintillator

Water-based liquid scintillator (WbLS) is a hybrid detector medium which has been proposed as a fill material for future large-volume rare event searches, including ν − detectors. This family of scintillating suspensions promises waterlike attenuation and scattering behavior, while offering scintillation light yield for sub-Cherenkov-threshold events. These features may allow for improved vertex and energy resolution, and concomitant improvements in background rejection and particle identification. While subscale measurements of light yield, timing and pulse-shape have been performed in several WbLS formulations, detailed measurements of the attenuation and scattering properties of WbLS remain a critical, unresolved step along the pathway to deployment. In pursuit of a better understanding of these parameters, a “long-arm” attenuation and scattering instrument has been developed at Lawrence Livermore National Laboratory, dubbed LASE (Livermore Attenuation and Scattering Experiment). Optical property measurements have been performed using LASE in DI water, Gd-water, WbLS and Gd-WbLS. Measurements of the optical properties of WbLS (1% LAB-PPO scintillator) provided by Brookhaven National Laboratory demonstrate an attenuation minimum of 4.87 × 10 − 4 ± 1.42 × 10 − 4 cm − 1 at 450 nm, while Gd-loaded WbLS (1% LAB-PPO scintillator, 0.1% Gd) demonstrated a minimum attenuation coefficient of 4.77 × 10 − 4 ± 1.27 × 10 − 4 cm − 1 at the same wavelength. Measurements of scattering in WbLS show a scattering coefficient of 3.39 × 10 − 4 ± 1.98 × 10 − 5 cm − 1 at the 450 nm attenuation minimum, while Gd-WbLS has a scattering coefficient of 2.8 × 10 − 4 ± 1.63 × 10 − 5 cm − 1 at that wavelength. These scattering and attenuation coefficients are significantly larger than measured for DI water at similar wavelengths ( 8.8 × 10 − 5 cm − 1 ± 3.8 × 10 − 5 attenuation at 430 nm, 2.2 × 10 − 5 ± 1.28 × 10 − 6 cm − 1 scattering). Though the WbLS attenuation and scattering coefficients measured are lower than the corresponding values published for ultrapure oils and LAB-PPO liquid scintillator, the material tested attenuates significantly more than water across the blue and green portions of the visible spectrum. This attenuation is markedly stronger at wavelengths under 430 nm. Published by the American Physical Society 2025

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Fracture Failure Analysis for MQXFA Magnet Aluminum Shells

The High-Luminosity LHC Accelerator Upgrade Project (HL-LHC AUP) is approaching the production phase of the US-contributed Q1 and Q3 Interaction Region Quadrupoles (MQXFA). The structures for the MQXFA prototypes were design and inspected by the US-LARP (LHC Accelerator Research Program), AUP developed criteria, which will be used for the pre-series structures. As the first two full-length prototypes with 4.2 m magnetic length, MQXFAP1 and MQXFAP2, were designed and assembled at Lawrence Berkeley National Laboratory (LBNL), and tested at Brookhaven National Laboratory (BNL). The end aluminum short shell of MQXFAP2 was fractured along the shell length during the test, and tests were stopped. Analytical and Finite Element analysis were performed in light of the graded procedure defined in the Structure Design Criteria to investigate the fracture failure for MQXFAP2. In this paper, we report the fracture analysis of the current shell design, including the elasto-plastic simulations with submodel technique, and calculations with Linear Elastic Fracture Mechanics (LEFM). Test material properties are also presented. The results of this analysis explain why the end shell of MQXFAP2 failed, and suggest fillets on the end shell notches to meet the margin specified in the Structural Design Criteria.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Design of a High Toughness Epoxy for Superconducting Magnets and Its Key Properties

Nb 3 Sn accelerator magnets are poised to enable the luminosity upgrade of the Large Hadron Collider (LHC) at CERN, improving its potential for exploring physics beyond the standard model of particle physics. The prototype Nb 3 Sn magnets consistently need 10–25 quenches to achieve their best performance. A hypothesis is that the long training of these magnets may at least be partially induced by epoxy cracking and bonding failures. In 2018, we showed that several existing epoxies have a higher toughness and less tendency to crack at low temperatures than CTD-101K, the epoxy resin with which almost all Nb 3 Sn accelerator magnets have been impregnated. Here we explore a new high toughness formulation for reducing quench training of Nb 3 Sn accelerator magnets, through combining two amine curing agents to achieve a good glass transition temperature (T g ), adding a viscosity reducer to achieve low viscosity, and experimenting a coupling agent for improved bonding strengths. In this work, we report results of comprehensive materials tests, including thermal shock, tensile, compressive, shear tests, viscosity and T g tests.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗