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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

In-Situ Visualization of a Growing Brittle Crack in Aluminum Oxynitride Using Synchrotron X-Rays and the Double-Cleavage Drilled Compression Geometry

Brittle fracture is difficult to study in situ due to the speed of a growing crack and the often-catastrophic nature of failure in brittle materials. As a result, the influence of microstructural considerations, such as orientation, grain boundary locations, and strain field, on the crack path remains poorly understood. Presented in this study is a method addressing this knowledge gap, which utilizes the double-cleavage drilled compression geometry to achieve quasi-stable fracture in aluminum oxynitride (AlON). Synchrotron X-ray micro-computed tomography is used to characterize the crack shape and length, while high-energy diffraction microscopy provides information on the strains, orientations, and shapes of grains in the microstructure surrounding the crack tip. During testing, the crack grew in discrete and irregular jumps while the fracture toughness falls within reported ranges. The crack in AlON is found to have no greater tendency to crack intergranularly as compared to transgranularly, and grains which are cracked transgranularly do not display a trend in orientation or stress when compared to those around which the crack followed a grain boundary. The high resolution of the crack path and microstructural data provides a path forward for modeling and understanding 3D brittle fracture.

Gorske, Sara F.↗
DOE OSTI2020

Process optimization of complex geometries using feed forward control for laser powder bed fusion additive manufacturing

Additive manufacturing (AM) enables the fabrication of complex designs that are difficult to create by other means. Metal parts manufactured by laser powder bed fusion (LPBF) can incorporate intricate design features and demonstrate desirable mechanical properties. However, printing a part that is qualified for its intended application often involves reprinting and discarding many parts to eliminate defects, improve dimensional accuracy, and increase repeatability. The process of iteratively converging on the appropriate build parameters increases the time and cost of creating functional LPBF manufactured parts. This work describes a fast, scalable method for part-scale process optimization of arbitrary geometries. Additionally, the computational approach uses feature extraction to identify scan vectors in need of parameter adaptation and applies results from simulation-based feed forward control models. This method provides a framework to quickly optimize complex parts through the targeted application of models with a range of fidelity and by automating the transfer of optimization strategies to new part designs. The computational approach and algorithmic framework are described, a software package is implemented, the method is applied to parts with complex features, and parts are printed on a customized open architecture LPBF machine.

3D printing↗
DOE OSTI2020

Geometry-independent microstructure optimization for electron beam powder bed fusion additive manufacturing

The ability to manipulate the formation of microstructure is one of the potential advantages of additive manufacturing. Yet, the additive manufacturing process is riddled with complex interactions between processing parameters, geometry, and spot melting sequence which makes the task of controlling microstructure challenging. This paper proposes a method to solve the microstructure texture optimization problem by leveraging established optimization techniques and increasingly fast and accurate analytical heat transfer models. Respectively, we apply two different optimization algorithms, genetic algorithm and concurrent greedy line search, in order to induce arbitrarily shaped microstructure regions and we use a heat transfer model to evaluate the fitness of solutions in an iterative approach that is far more efficient than pure trial and error. The objective of the optimization algorithm is to control local thermal conditions – hence microstructure formation – during the melting process by manipulating the order and the dwell time of all the points of the infill pattern sequence. We then analyze the optimized sequence to determine important path characteristics that affect the microstructure formation. Through examples, we show that relative order and frequency, as measured by weighted average and variance of spot order, are important factors that influence the final characteristics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A stochastic scan strategy for grain structure control in complex geometries using electron beam powder bed fusion

Spatial control of microstructure within a three-dimensional component has been a dream of materials scientists for centuries. However, limitations in traditional manufacturing processes prevent detailed control over the distribution of microstructures in a single part. Here, we demonstrate the ability to control grain structure and crystallographic texture during metal additive manufacturing for arbitrary cross-sections of a practical size, with profound implications for the design and optimization of next-generation products. The key to this advance is a new geometry agnostic scan path algorithm that manipulates the spatial distribution of solidification conditions. Utilizing a fundamental understanding of solidification dynamics and a model of the heat transfer during processing, we have designed this algorithm to manipulate the natural competition between epitaxial dendrite growth and grain nucleation. With this algorithm, we successfully controlled the grain structure of Ni-based superalloy IN718 in the shape of the Mona Lisa.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Influence of geometry on columnar to equiaxed transition during electron beam powder bed fusion of IN718

Correlation between spot-melt scan parameters (linear spot-density aka areal energy density), build geometry, and solidification microstructure evolution (columnar vs equiaxed) in a powder bed fusion technology is investigated. It is shown that to maintain the equiaxed solidification microstructure evolution in electron beam powder bed additive manufacturing (AM), the areal energy density per layer needs to be scaled with respect to the 2D cross-sectional area of the layer being melted. Samples with two different cross-sectional areas (40 × 40 mm and 20 × 20 mm) have been fabricated with varying areal energy densities. For a given square cross-section (20 × 20 mm), increasing the areal energy density (4.8 MJ/sq.m to 14.7 MJ/sq.m) transitioned the solidification microstructure from columnar to equiaxed. The observed microstructure data (Electron Back Scattered Diffraction - EBSD) is quantified by calculating the principal component (PC) score using a spatial statistics methodology. The sample with equiaxed grains is found to have a low PC score while the sample with columnar grain had a high PC score. A semi-analytical model is used to simulate the heat transfer and the local solidification conditions as a function of processing parameters (linear spot-density). The result from the heat transfer model is correlated with previously quantified microstructure data. Space-Time analysis of the melt pattern is done and correlated with the observed microstructure. In addition, from the findings, appropriate parameters have been used to additively manufacture a turbine blade with site-specific or hybrid solidification microstructure (traditional fabrication possible via a patented method of localized cold working and heat treatment).

36 MATERIALS SCIENCE↗
DOE OSTI2025

Exploring the impact of surface topography on Rayleigh-Bénard dry convection in the Pi cloud chamber using OpenFOAM: In cylindrical and rectangular geometries

The Pi convection-cloud chamber can generate steady-state turbulence in both rectangular and cylindrical shapes via Rayleigh-Bénard convection (RBC) by maintaining warm bottom and cold top surfaces. Although most experiments in the Pi chamber were conducted in cylindrical shapes, all previous Pi chamber simulations were conducted in a rectangular shape due to the limitations of those models to discretize a cylindrical domain when using the finite difference method therein. Here, we use OpenFOAM, an open-source finite-volume-based Computational Fluid Dynamics (CFD) software package, to conduct Large-Eddy Simulation (LES) of dry RBC in the Pi chamber at high Rayleigh numbers (10 8 to 10 9 ). Results show that large-scale circulation (LSC) direction varies in the chamber with a constant side wall temperature. Imposing a slight temperature imbalance at the side wall ranging from 0.1 to 0.7 degrees can lock the LSC, aligning better with Pi chamber observations, particularly at higher Rayleigh numbers. In addition, we examine the impact of surface topography on LSC and heat transfer in RBC systems within cylindrical and rectangular shapes under varying conditions. Results show that roughing top/bottom surfaces by adding bars of a few tens millimeters height can strengthen thermal plumes and enhance temperature fluctuations in the chamber. Furthermore, we observe that different bar height configurations lead to notable changes in LSC orientation and thermal stratification, highlighting the complex interactions between surface features and convection patterns. This finding highlights how surface topography and chamber geometry affect Rayleigh-Bénard convection, improving understanding of turbulent heat transfer and atmospheric boundary-layer processes. Direct Numerical Simulations (DNS) are also conducted to validate LES results. In conclusion, while LES effectively captures qualitative behaviors seen in DNS, it tends to underestimate velocity variances near walls, illustrating a trade-off between computational efficiency and accuracy.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Filament geometry control in extrusion-based additive manufacturing of concrete: The good, the bad and the ugly

Control of filament geometry in extrusion based additive manufacturing is essential to guarantee the desired quality of the printing process and the final product. Depending on the selected process parameters, material strategy and geometrical features, the printing process can however be susceptible to filament tearing or filament buckling. In this work, 2D and 3D CFD simulations have been used to map the influence of all these parameters in the infinite brick regime of 3D concrete printing processes. Analytical derivations of a tearing factor and buckling factor are presented. The use of these analytical tools is then illustrated, by studying variations in the printing process, such as changes in velocities, nozzle height, or material properties. Finally, the risk of both filament tearing and buckling of a single filament when printing sharp turns is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2026

The role of source geometry and atmospheric propagation in global bolide infrasound detectability

Global infrasound monitoring provides a persistent means of detecting energetic bolide atmospheric entries, complementing optical observations and extending coverage over remote regions. We present a global assessment of the physical factors governing bolide infrasound detectability by correlating 623 bolide events reported by the Center for Near-Earth Object Studies between 2007 and 2025 with waveform data from the International Monitoring System. We identify 311 events with confirmed infrasound detections, corresponding to a detection rate of approximately 50%, substantially higher than inferred from earlier surveys, reflecting both the maturation of the global infrasound network and advances in automated, multi-frequency array processing. Analysis of flight parameters shows that infrasound detectability is selective rather than uniform across the bolide population. Detected events are preferentially associated with steeper entry angles and lower-altitude energy deposition, while shallow, high-altitude trajectories are less consistently observed. Very high-energy events remain detectable regardless of geometry, but for the more common lower-energy regime, observability depends on specific combinations of entry parameters and propagation conditions. This geometric dependence persists across comparable energy ranges and atmospheric conditions, indicating that entry angle exerts a primary control on detectability, with energy and propagation acting as secondary modulating factors. Furthermore, these results provide new physical constraints on bolide-atmosphere interactions and improve interpretation of global infrasound observations for planetary defense and atmospheric-entry studies.

Bolides↗
DOE OSTI2020

Deposit geometry and oxygen concentration spatial variations due to composition change in printed functionally graded components

Functionally graded materials (FGMs) with site specific chemical composition are commonly manufactured by directed energy deposition (DED). Although previous work fabricated an FGM with a compositional variation between a ferritic and austenitic alloy, difficulties arose due to variations in deposit shape with composition change. This problem also occurs for FGMs in literature; however, unlike other cases, the thermophysical properties of these two alloys were similar throughout the build. Here, we investigate the role of chemical composition and surface-active elements on deposit geometry during the manufacture of FGMs by laser DED. Single-track experiments for the relevant FGM compositions are analyzed with results from a well-tested, three-dimensional, transient numerical heat transfer and fluid flow model and thermodynamic calculations. Experiments showed deposit shape varied as a function of composition for constant laser power and scan speed. Thermodynamic analysis indicated that the oxygen solubility in the fusion zone varied significantly for each composition used for the FGM. Numerical modeling revealed that the change in fluid flow caused by Marangoni convection due to dissolved oxygen in the fusion zone were mainly responsible for the changes in deposit shape observed in experiments. Finally, because oxygen can be introduced into the fusion zone through the feedstock as well as the surrounding atmosphere, these findings elucidate a previously unconsidered aspect of process control during DED fabrication of FGMs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of micro-fin tube geometry parameters on evaporator material savings

A Performance Evaluation Criteria (PEC) analysis is presented that explores the influence of the micro-fin tube geometry on the required material volume. The analysis was done using a local flow boiling model, which can quantify the effect of fin parameters and the tube diameter. The PEC was done while requiring that the compared surfaces satisfy the same heat duty and pressure drop. The following tube parameters and ranges were explored: tube diameter (3 mm ≤ D o ≤ 6 mm), fin base thickness (0.12 mm ≤ t bf ≤ 0.29 mm), helix angle (6° ≤ α ≤ 30°), fin apex angle (11° ≤ β ≤ 22°), total number of fins (43 ≤ n f ≤ 70), and the fin height (0.11 mm ≤ e ≤ 0.3 mm). The tube that provided the smallest material requirements within the examined parameter ranges had: D o = 3 mm, t bf = 0.12 mm, α = 6°, β = 11°, n f = 43, and e = 0.3 mm. In general, small D o and t bf and large n f and e provided the best performance and work to minimize the required material volume to provide a given heat duty and pressure drop. The helix and the fin-tip apex angles were found to have very little influence on the performance for the examined range of parameters and angles associated with the lowest production cost should be chosen.

Evaporation↗
DOE OSTI2022

Enabling a novel approach to a controlled fabrication of 1D crystalline nanowires on suspended microstructures of arbitrary geometries using two direct-writing technologies

Recent progresses in additive manufacturing have inspired new technologies, such as direct laser writing technique, based on two-photon polymerization (2 PP), which complements and further enriches the nanofabrication tools portfolio. Here, we combine 2 PP and our mask-free scanning probe assisted ‘direct-write patterning’ (DWP) method to allow for: a) the fabrication of micro-bridge structures with sub-micrometer resolution, b) selective synthesis of crystalline ZnO nanowires at predefined locations, respectively. This synergistic approach enables cantilever probe patterning of catalysts directly on suspended micro-bridges for in-situ CVD growth of nanoscale material, in a templated manner. The study reported here represents the first proof-of-concept experiments demonstrating versatile and scalable methodology, which can be applied and straightforwardly extended to grow a variety of other nanomaterials, in a controlled and selective fashion, on freestanding micro/nanoscale structures, whose size and geometry can be conveniently varied via templating of sacrificial 2 PP polymeric scaffolds. Furthermore, the demonstration of the possibility to integrate this new approach with the conventional lithography techniques provides a step forward to the development of the novel class of hybrid polymer-silicon-1D or -2D materials, and systems. The quality of the produced ZnO nanowire assemblies was assessed using several physical characterization methods.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Magnetic charge and geometry confluence for ultra-low forward voltage diode in artificial honeycomb lattice

We report spin diode is important prerequisite to practical manifestation of spin electronics. Yet, a functioning magnetic diode at room temperature is still illusive. Here, we reveal diode-type phenomena due to magnetic charge mediated conduction in artificial honeycomb geometry, made of concave shape single domain permalloy element. We find that honeycomb lattice defies symmetry by populating vertices with low and high multiplicity magnetic charges, causing asymmetric magnetization, in applied current of opposite polarity. High multiplicity units create highly resistive network, thereby inhibiting magnetic charge dynamics propelled electrical conduction. However, practical realization of this effect requires modest demagnetization factor in constituting element. Concave structure fulfills the condition. Subsequently, magnetic diode behavior emerges across broad thermal range of T = 40 K–300 K. The finding is a departure from the prevailing notion of spin-charge interaction as the sole guiding principle behind spintronics. Consequently, a new vista, mediated by magnetic charge interaction, is envisaged for spintronic research.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A virtual Frisch-grid geometry-based CZT gamma detector for in-field radioisotope identification

Here, we present a Virtual Frisch-Grid geometry-based CZT gamma detector developed for identifying different radioisotopes over an energy range from a few keV up to 2 MeV, and useful for efficient characterization of CZT crystals. The detector is built with a 3 x 3 matrix of CZT crystals, each measuring approximately 6 mm x 6 mm x 15 mm. The charge generated within the sensor’s active volume is read out via an anode connected directly to the AVG3_Dev integrated circuit. A current signal induced by charge drift is collected on side pads of the crystals, enabling reconstruction of a 3D interaction position. This paper discusses the design, development, and performance of the standalone, mobile detector system, which integrates the AVG3_Dev readout IC developed at Brookhaven National Laboratory, a high-speed FPGA-based with per-channel digital signal processing, and embedded system capabilities. The device is compact, battery-powered, and supports wireless data streaming, making it suitable for field operations for radioisotope identification.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Geometry-based, Gaussian profile model for optical knife-edge displacement sensor

This article describes an analytical model for the well-known optical knife-edge displacement sensor that predicts the relationship between the knife-edge displacement and photointerrupter output. The model includes: 1) the geometry of a rectangular knife-edge profile penetrating a circular laser beam perpendicular to the beam axis; and 2) the Gaussian intensity profile for the beam cross-section. A comparison between the model predictions and measured photointerrupter for a linear range of knife-edge displacements is provided. It is shown that good agreement is obtained without model calibration.

42 ENGINEERING↗
DOE OSTI2021

The on-axis magnetic well and Mercier's criterion for arbitrary stellarator geometries

A simplified analytical form of the on-axis magnetic well and Mercier's criterion for interchange instabilities for arbitrary three-dimensional magnetic field geometries is derived. For this purpose, a near-axis expansion based on a direct coordinate approach is used by expressing the toroidal magnetic flux in terms of powers of the radial distance to the magnetic axis. For the first time, the magnetic well and Mercier's criterion are then written as a one-dimensional integral with respect to the axis arclength. When compared with the original work of Mercier, the derivation here is presented using modern notation and in a more streamlined manner that highlights essential steps. Finally, these expressions are verified numerically using several quasisymmetric and non-quasisymmetric stellarator configurations including Wendelstein 7-X.

Physics↗
DOE OSTI2024

Direct, simple and efficient computation of all components of the virtual-casing magnetic field in axisymmetric geometries with Kapur–Rokhlin quadrature

In a recent publication (Toler et al., J. Plasma Phys., vol. 89, issue 2, 2023, p. 905890210), we demonstrated that for axisymmetric geometries, the Kapur–Rokhlin quadrature rule provided an efficient and high-order accurate method for computing the normal component, on the plasma surface, of the magnetic field due to the toroidal current flowing in the plasma, via the virtual-casing principle. The calculation was indirect, as it required the prior computation of the magnetic vector potential from the virtual-casing principle, followed by the computation of its tangential derivative by Fourier differentiation, to obtain the normal component of the magnetic field. Our approach did not provide the other components of the virtual-casing magnetic field. In this letter, we show that a more direct and more general approach is available for the computation of the virtual-casing magnetic field. The Kapur–Rokhlin quadrature rule accurately calculates the principal value integrals in the expression for all the components of the magnetic field on the plasma boundary, and the numerical error converges at a rate nearly as high as the indirect method we presented previously.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Turbulence and transport in mirror geometries in the Large Plasma Device

Thanks to advances in plasma science and enabling technology, mirror machines are being reconsidered for fusion power plants and as possible fusion volumetric neutron sources. However, cross-field transport and turbulence in mirrors remains relatively understudied compared with toroidal devices. Turbulence and transport in mirror configurations were studied utilizing the flexible magnetic geometry of the Large Plasma Device (LAPD). Multiple mirror ratios from $M=1$ to $M=2.68$ and three mirror-cell lengths from $L=3.51$ to $L=10.86$ m were examined. Langmuir and magnetic probes were used to measure profiles of density, temperature, potential and magnetic field. The electric field-fluctuation-driven ${\tilde {\boldsymbol{E}}} \times {\boldsymbol{B}}$ particle flux, where $\boldsymbol{B}$ is the background field, was calculated from these quantities. Two probe correlation techniques were used to infer wavenumbers and two-dimensional structure. Cross-field particle flux and density fluctuation power decreased with increased mirror ratio. Core density and temperatures remain similar with mirror ratio, but radial line-integrated density increased. The physical expansion of the plasma in the mirror cell by using a higher field in the source region may have led to reduced density fluctuation power through the increased gradient scale length. This increased scale length reduced the growth rate and saturation level of rotational interchange and drift-like instabilities. Despite the introduction of magnetic curvature, no evidence of mirror-driven instabilities – interchange, velocity space or otherwise – were observed. For curvature-induced interchange, many possible stabilization mechanisms were present, suppressing the visibility of the instability.

Travis, Phil (ORCID:0000000343170432)↗
DOE OSTI2026

Constructing field-aligned coordinate systems for gyrokinetic simulations of tokamaks in X-point geometries

Structures in tokamak plasmas are elongated along the direction of the magnetic field and short in the directions perpendicular to the magnetic field. Many tokamak simulation codes take advantage of this by using a field-aligned coordinate system. However, field-aligned coordinate systems have a coordinate singularity at magnetic X-points where the poloidal magnetic field vanishes, which makes it difficult to use field-aligned coordinate systems when simulating the core and scrape-off layer simultaneously. Here, we present an algorithm for grid generation and computing geometric quantities in a standard field-aligned coordinate system that avoids the singularity and allows one to conduct two-dimensional gyrokinetic axisymmetric simulations in X-point geometries. Convergence tests of advection, boundary value problems and geometric quantities all show greater than first-order convergence even in the vicinity of the X-point. We also demonstrate the geometric consistency of our algorithm with an example simulation of the spherical tokamak for energy production, which shows machine-precision particle conservation.

fusion plasma↗