Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Fusion reactor design”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Lessons Learned from Open-Source Software Training Toward Expanding the Fusion Workforce

Within the United States (U.S.), the Fusion Innovation Research Engine (FIRE) Collaboratives seek to accelerate fusion technology development through wide-ranging community-driven research activities that bring together industry, laboratories, research institutes, and academia. Increasing the maturity of key components and systems for future fusion power plants (FPPs) toward commercialization, will, by necessity, increase the need for knowledgeable engineers, designers, and researchers in industry capable of integrating and further improving these technologies within industry FPP concepts. Further, various modeling and simulation packages support these programs and are under-development within them to drive design iteration and the development of FPP digital twins. To derive the greatest benefit from model output and capabilities, training these same specialists will be vital. Thus, the development of effective and accessible software onboarding and professional development opportunities focused on fusion will be key to keeping the pace of growth high in the coming decade and beyond. A similar need exists within the advanced fission reactor community, driven by an ever-growing need for carbon-free baseload power for industrial and data center applications. Within the U.S. and around the world, several open-source packages and frameworks exist to support this endeavor, and two we will highlight here are the Multiphysics Object Oriented Simulation Environment (MOOSE) framework and OpenMC. These packages, notably, are also being utilized in the FIRE Collaboratives program. In this presentation, we will highlight the lessons learned from over 30 years of combined software development and training experience, focused on developing strong technical software foundations within the nuclear workforce, from students to professional engineers & scientists. We will connect this experience to present and emerging needs in the fusion energy community, and, finally, will outline possible paths forward to develop a large, robust, global fusion workforce.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Vertical control of DIII-D discharges with strong negative triangularity

Through predictive modeling validated by a series of experiments on DIII-D, the vertical stability of low β diverted plasmas with strong negative triangularity (NT) ($\delta\sim-0.6$) is assessed. As a result of their unique magnetic geometry, NT plasmas feature larger Shafranov shifts and more elongated inner flux surfaces than positive triangularity counterparts, typically leading to enhanced vertical instability growth rates. However, coupling with the non-conformal vessel DIII-D wall reduces these growth rates to controllable values, providing a path forward for stabilizing strongly NT plasma with a diverted geometry. These discharges are used to validate GSdesign (part of the TokSys code suite) stability calculations in strong NT plasmas on DIII-D, with errors of no more than ~20% observed between modeled and experimentally measured growth rates. Additions of diagnostic noise and power supply tuning to the TokSys model are needed to accurately capture the time dependence of DIII-D NT discharges, assisting with the design of control schemes specific to the DIII-D poloidal field coils. Lastly, implications of these results on a future NT reactor are briefly described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Simulation of Direct-Drive Hybrid Using Two Opposed Beams for Inertial Fusion Energy

Xcimer Energy is working to deliver high levels of laser light at the costs required for applications in fusion energy. The architecture of their integrated laser system is unique, in that it naturally supports a target which is illuminated by two opposed beams, and in a manner that can readily complement a reactor. This INFUSE proposal was submitted to investigate a target concept termed the Direct-Drive Hybrid or DDH, and make special use of radiation hydrodynamic simulations and expertise available to the Laboratory for Laser Energetics. The associated capabilities are unique to the field, and take great advantage of investments and advances made by the DOE and DOD over many decades. The primary goals were to stand up the DDH design in calculations for the first time, study and refine the concept, and provide the scientific basis for understanding and projecting proposals by Xcimer Energy. The main accomplishments have been summarized below.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1972

Post impact behavior of mobile reactor core containment systems.

In the future, nuclear assemblies containing fission products will be transported at high speeds. An example is a reactor supplying power to a large subsonic airplane. In this case an accident can occur resulting in a ground impact at speeds up to 1000 ft/sec. This paper analyzes the containment vessel temperatures after impact and attempts to understand the design variables that affect the post impact survival of the system. The heat transfer analysis includes conduction, radiation, and convection in addition to the core material heats of fusion and vaporization under partial-burial conditions. Also, included is the fact that fission products vaporize and transport radially outward and condense on cooler surfaces, resulting in a moving heat source.

Puthoff, R. L.↗
DOE OSTI2026

Results from the last DD and DT JET campaigns in the framework of the EUROfusion Tokamak Exploitation Work Package activity

JET, the only tokamak capable of operating with deuterium–tritium (D–T) fuel (since TFTR was shutdown in 1999), has provided essential experimental data to support ITER and DEMO design and operation. Within the EUROfusion Tokamak Exploitation Work Package, JET completed its final campaigns (2022–2023), culminating in the third D–T campaign (DTE3). These experiments addressed key challenges in plasma scenarios, exhaust control, and tritium management under reactor-relevant conditions. Significant progress was achieved in demonstrating ITER-like integrated scenarios with impurity seeding, achieving partial divertor detachment and high confinement ($H_{98}(y,2)$ ≈ 0.85) at 3 MA in D–T plasmas. Advanced exhaust regimes such as quasi-continuous exhaust (QCE) and X-point radiator (XPR) were successfully achieved first in D–D and then extended to D–T operation, confirming their relevance for mixed isotope operation. Operational milestones included a new world record of 69 MJ fusion energy in tritium-rich hybrid plasmas and long-pulse H-mode operation up to 60 s, contributing with unique data to the CICLOP database. Physics studies focused on peeling-limited pedestals in support of ITER and improved understanding of edge stability and impurity screening in metallic environments. Extensive usage of the shattered pellet injector (SPI) on JET provided critical information for the design of the ITER disruption mitigation system (DMS). Real-time control systems for D/T ratio control and plasma exhaust were deployed and demonstrated in D–D and D–T, while energetic particle physics investigations unfolded the role of fast ions in turbulence suppression mechanisms. Comprehensive tritium retention studies using gas balance method, post-mortem analysis, and ITER-relevant laser induced desorption spectroscopy (LIDS) diagnostics provided essential input for tritium accountancy strategies. These results are validating the ITER operational concepts, inform DEMO design, and deliver critical experience in nuclear operation and scenario integration.

disruptions↗
DOE OSTI2025

Thermal-Fluid and Thermal-Structural Response of the T-Tube Modular Divertor to Spatiotemporally Varying Heat Loads

Tungsten (W) is the leading candidate for divertor target plates because of its high melting point (>3000°C), thermal conductivity, and ultimate tensile stress. While W and its alloys are the only solid materials that can survive the high heat fluxes incident on the divertor, W’s low-ductility high ductile-to-brittle transition temperature of ~600°C and relatively low recrystallization temperature (RT) of ~1300°C pose structural (among other) challenges. The objective of this work is to estimate the thermal-fluid and thermal-structural performance of the helium (He)-cooled T-tube divertor, which was originally developed by the Advanced Reactor Innovation and Evaluation Study (ARIES) using numerical simulations. Here, predictions of temperature distributions across the plasma-facing structural component and surface pressures from computational fluid dynamics simulations are used to determine stress distributions using commercial structural finite element modeling software over a range of fusion-relevant conditions. The maximum allowable incident heat fluxes are determined based on the temperature limits imposed by the ITER elastic Structural Design Criteria for In-vessel Components (SDC-IC) and the maximum RT over a range of He mass flow rates and presented in the form of performance design charts. Our recent work found that thermal- structural criteria accounting for the low ductility of W in a finger-type modular divertor constrain the maximum incident heat fluxes to values well below the ITER specifications, and those based on considering only the RT demonstrate that integrated thermal-fluid and elastic structural performance evaluation are required for accurate assessment of divertor performance. This novel analysis of the T-tube considers how nonuniform and transient incident heat fluxes affect its thermal-fluid and thermal-structural performance, as well as the effect of volumetric heating, which can be as great as 27% of the power incident on the divertor surface. The W tile of the T-tube, with its relatively large plasma-facing area of ~15 cm 2 , will likely experience significant spatial variations in incident heat flux. This work therefore assesses whether steady-state incident heat flux profiles with a peak of 10 MW/m 2 and maximum heat flux gradients of 200 MW/m 2 per m exceed the structural limits imposed by the ITER elastic SDC-IC and the maximum RT over a range of fusion-relevant conditions. The effect of transient heat fluxes typical of plasma detachment and reattachment from the target plate due, for example, to gas injection are also evaluated

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Progress Towards a Titanium-Zirconium-Molybdenum Alloy Coreblock Prototype Using Powder Bed Fusion

Microreactor designs make use of a coreblock for structural stability allowing for these devices to provide powder generation while being portable and inherently safe. In order to maximize energy output of the microreactors, materials must be able to withstand high temperature without melting and without substantial decreases in mechanical properties. As simultaneous projects looking at steels, graphite, and other materials are on-going, this work package will investigate titanium – zirconium – molybdenum alloy (TZM) as it allows for potentially higher microreactor operating temperatures than traditional reactor materials such as stainless steel. Notably, this alloy was developed in the 1960s for use in rockets and has a very high melting point (2623°C) but is difficult to form, machine and join. With limited needs in aerospace, literature is appropriately sparce in looking at the AM of TZM (examples include [1,2]). However, the properties appear to be an excellent match for the needs of the microreactor coreblock leading to the current project. In addition, small washers form the bulk of TZM parts needed in aerospace while the microreactor community was looking at larger, more complex parts. Therefore, AM of TZM is being explored to enable near – net shape of components with the needed complexity to impact the nuclear energy field.

36 MATERIALS SCIENCE↗
NASA NTRS1977

Engineering of beam direct conversion for a 120-kV, 1-MW ion beam

Practical systems for beam direct conversion are required to recover the energy from ion beams at high efficiency and at very high beam power densities in the environment of a high-power neutral-injection system. Such an experiment is now in progress using a 120-kV beam with a maximum total current of 20 A. After neutralization, the H(+) component to be recovered will have a power of approximately 1 MW. A system testing these concepts has been designed and tested at 15 kV, 2 kW in preparation for the full-power tests. The engineering problems involved in the full-power tests affect electron suppression, gas pumping, voltage holding, diagnostics, and measurement conditions. Planning for future experiments at higher power includes the use of cryopumping and electron suppression by a magnetic field rather than by an electrostatic field. Beam direct conversion for large fusion experiments and reactors will save millions of dollars in the cost of power supplies and electricity and will dispose of the charged beam under conditions that may not be possible by other techniques.

Barr, W. L.↗
DOE OSTI2024

Corrosion Testing Of Additively Manufactured Stainless Steel 316H In Molten Salt Environments

The development of a new ASTM standard for evaluating the corrosion resistance of additive manufactured (AM) stainless steel (SS) 316H in chloride molten salts is critical for the use of these materials in extreme environments such as molten salt reactors (MSRs). This report pertains to a work package of the Advaned Materials and Manufacturing Technologies (AMMT) developing a systematic methodology to link changes in AM fabrication parameters, namely surface finishing, porosity, microstructure, and chemical heterogeneity, to corrosion performance in NaCl-MgCl2 salt, a proposed secondary coolant for MSRs. During Fiscal Year 2024, Idaho National Laboratory investigators in the AMMT program, utilized SS316H bars, fabricated with laser bed powder fusion at Los Alamos National Laboratory, to establish and optimize the workflow for evaluating these process-to-performance relationships. Standard practices for specimen preparation were established using these specimens, with particular focus on descaling and sectioning methods that align with ASTM guidelines. A comprehensive experimental design for static corrosion testing was developed, with pre- and post-exposure analysis utilizing optical microscopy and scanning electron microscopy. So far standard descaling techniques were optimized, one static corrosion test was conducted on the LANL AM SS316H specimens, and pre- and post-corrosion practices were established. In addition, the work package yielded a review paper on corrosion testing gaps for AM materials in nuclear applications and submitted a proposal for a rapid-turnaround experiment to the Nuclear Science User Facilities Program to investigate the combined effects of proton irradiation and corrosion on AM SS316H. This work package establishes a foundation for evaluating processing-to-performance relationships for AM SS316H in harsh conditions, contributing to the safe and efficient design of components for next-generation nuclear reactors. The creation of a standardized methodology and the generation of relevant publications and future research pathways represent significant strides towards integrating AM materials into critical applications where corrosion resistance is paramount.

36 MATERIALS SCIENCE↗
DOE OSTI2024

REBCO Insert Coils toward High-Field, Large-Bore Magnet for Quantum Physics Research

High-temperature superconducting (HTS) magnets offer a promising solution for generating high magnetic fields efficiently and economically, serving as a vital component in nextgeneration scientific instruments and carbon-neutral power systems, notably in cost-effective compact fusion reactors. These high magnetic fields play a pivotal role in advancing research on quantum materials, particularly in elucidating the intricate electronic states near magnetic phase transitions. Here, this paper delves into the research conducted at the Princeton Plasma Physics Laboratory, which is divided into three phases aimed at overcoming technical hurdles in creating large-bore, high-field HTS magnets for cutting-edge quantum physics research. In Phase 1, we designed, constructed, and tested a compact REBCO solenoidal magnet comprising six double-pancake coils featuring a 41.3-mm inner diameter and a 70.0-mm outer diameter. It adopts a no-insulation approach to ensure electrical and thermal stability. Successful testing in a saturated liquid nitrogen bath confirmed its capability to generate a 0.8-T field at 77 K and 2 T at 65 K, with ongoing integration into liquid helium testing. Building on this experience, Phase 2 involves the design of an HTS insert coil, intended to nest within a 12-T low-temperature superconducting (LTS) outsert to achieve a minimum of 20 T at 4.2 K. The focus of Phase 2 centers on addressing challenges posed by screening-current (SC) effects, particularly the associated stress/strain issues. Employing a numerical model that fully couples the SC and mechanical analysis, we discuss strategies for managing stress to mitigate the effects of SCinduced stress concentrations.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1988

Project Longshot: An unmanned probe to Alpha Centauri

A preliminary design is presented for an unmanned probe to Alpha Centauri with a planned launch early in the 21st century. The probe would be assembled at the space station and take approx. 100 yrs to reach the nearest star. Several technologies must be developed in order for this mission to be possible. A pulsed fusion microexplosion drive with 1,000,000 secs of specific impulse is the primary enabling technology. A large, long life fission reactor with 300 kW power output is also required. Communications lasers would use a 0.532 micrometer wavelength since there is minimal power output by the stars in that frequency band. A laser with an input power of 250 kW would allow for a data rate of 1000 bits per second at maximum range. There are 3 types of information to be gathered by the probe: properties of the interstellar medium, characteristics of the three star Alpha Centauri system, and astrometry.

Beals, Keith A.↗
DOE OSTI2023

Feasibility of Isotopically Tailored Low Activation Materials

Materials employed in future fusion reactors and advanced fission reactors are susceptible to activation and transmutation due to fast neutron flux, which drives the need for Low Activation Materials for survivability, maintenance, and long-term disposal considerations. This paper investigates the feasibility of using ORNL’s planned enrichment technologies to produce isotopically enriched or depleted materials for use in future reactor construction. We focus on identifying isotopes of interest and performing estimates of the required scale of enrichment to impact future design and operation.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2022

Particle trapping, size-filtering, and focusing in the nonthermal plasma synthesis of sub-10 nanometer particles

Low-pressure nonthermal flowing plasmas are widely used for the gas-phase synthesis of nanoparticles and quantum dots of materials that are difficult or impractical to synthesize using other techniques. To date, the impact of temporary electrostatic particle trapping in these plasmas has not been recognized, a process that may be leveraged to control particle properties. Furthermore, we present experimental and computational evidence that, during their growth in the plasma, sub-10 nm silicon particles become temporarily confined in an electrostatic trap in radio-frequency excited plasmas until they grow to a size at which the increasing drag force imparted by the flowing gas entrains the particles, carrying them out of the trap. We demonstrate that this trapping enables the size filtering of the synthesized particles, leading to highly monodisperse particle sizes, as well as the electrostatic focusing of the particles onto the reactor centerline. Understanding of the mechanisms and utilization of such particle trapping will enable the design of plasma processes with improved size control and the ability to grow heterostructured nanoparticles.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Radiation effects on stress evolution and dimensional stability of large fusion energy structures

Here we assess the effects of neutron irradiation on the deformation and stress evolution of large-scale fusion energy structures. This is accomplished through non-linear finite element structural analysis of the coupled thermal and mechanical fields at the Beginning-Of-Life (BOL), at 45 dpa, and at 90 dpa. Radiation effects include volumetric swelling and the influence of radiation on the mechanical properties. The system studied here is a large section of a full inboard module of an integrated structure comprising the First Wall and Blanket (FW/B) of a Dual Cooled Lithium-Lead (DCLL) energy conversion unit in the Fusion Nuclear Science Facility (FNSF). The structural material is the ferritic/martensitic steel F82H. We analyze several radiation effects phenomena that can lead to significant impact on the mechanical design and lifetime of the structure. These include volumetric swelling effects on the assembly and disassembly of modules and the impact of spatial gradients in neutron damage and helium generation on deformation, stress evolution, and plastic strain accumulation. We show that the stress state is strongly influenced by the accumulation of swelling strains, radiation hardening and softening, and by spatial gradients in displacement damage and helium gas generation. Several key regions in the FW/B structure are identified where severe plastic strains accumulate and may be potential sites for failure, especially during cyclic reactor operations. We finally show that minimum gaps between Inboard (IB) blanket sectors must be present during assembly so as to avoid excessive stress and strain in FW/B modules critical regions and raising chances of failure. A range of structural displacements are shown, from as low as 4 mm at BOL for free side walls to as high as 46 mm at 90 dpa for fully constrained side walls.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2021

Physics basis for design of 3D coils in tokamaks

Recent progress in 3D tokamak modeling is now leveraged to create a conceptual design of new external 3D field coils for the DIII-D tokamak. In this work generalized perturbed equilibrium code is used to determine optimally efficient spectrum for driving total, core, and edge neoclassical toroidal viscosity torque. These fundamental modes of 3D control are shown to have consistent outboard structures across a wide variety of plasma scenarios and machines. Given these target spectra, the currents and 3D geometry of multiple coils can be optimized to increase efficient drive for the physics of interest without undesired secondary effects. Here, this nonlinear optimization is demonstrated using the flexible optimized coils using space-curves code. The optimized coils are individually distorted in space, creating toroidal 'arrays' containing a variety of shapes that often wrap around a significant poloidal extent of the machine. Importantly, efficient coupling can be maintained even when enforcing large distances between coils and the plasma during the geometric optimization of coil designs. Finally, the physics-driven optimization presented here thus provides a practical path to utilizing coils built on the exterior of the vacuum chamber in future reactors to obtain the powerful 3D field benefits demonstrated on current machines with close, internal coils.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Learning plasma dynamics and robust rampdown trajectories with predict-first experiments at TCV

The rampdown phase of a tokamak pulse is difficult to simulate and often exacerbates multiple plasma instabilities. To reduce the risk of disrupting operations, we leverage advances in Scientific Machine Learning (SciML) to combine physics with data-driven models, developing a neural state-space model (NSSM) that predicts plasma dynamics during Tokamak à Configuration Variable (TCV) rampdowns. The NSSM efficiently learns dynamics from a modest dataset of 311 pulses with only five pulses in a reactor-relevant high-performance regime. The NSSM is parallelized across uncertainties, and reinforcement learning (RL) is applied to design trajectories that avoid instability limits. High-performance experiments at TCV show statistically significant improvements in relevant metrics. A predict-first experiment, increasing plasma current by 20% from baseline, demonstrates the NSSM’s ability to make small extrapolations. The developed approach paves the way for designing tokamak controls with robustness to considerable uncertainty and demonstrates the relevance of SciML for fusion experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1992

Lunar He-3, fusion propulsion, and space development

The recent identification of a substantial lunar resource of the fusion energy fuel He-3 may provide the first terrestrial market for a lunar commodity and, therefore, a major impetus to lunar development. The impact of this resource-when burned in D-He-3 fusion reactors for space power and propulsion-may be even more significant as an enabling technology for safe, efficient exploration and development of space. One possible reactor configuration among several options, the tandem mirror, illustrates the potential advantages of fusion propulsion. The most important advantage is the ability to provide either fast, piloted vessels or high-payload-fraction cargo vessels due to a range of specific impulses from 50 sec to 1,000,000 sec at thrust-to-weight ratios from 0.1 to 5x10(exp -5). Fusion power research has made steady, impressive progress. It is plausible, and even probable, that fusion rockets similar to the designs presented here will be available in the early part of the twenty-first century, enabling a major expansion of human presence into the solar system.

Santarius, John F.↗